Heating a vehicle roof rail

Abstract

The present invention relates to heating a vehicle roof rail. In various aspects, the disclosure provides a component. The vehicle component includes a polymeric matrix, a plurality of fibers in the polymeric matrix, and a heating element embedded in the polymeric matrix. The heating element can be: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii). The heating element is configured to be coupled to an external electrical circuit to generate heat. In one aspect, the vehicle component is a vehicle roof rail that includes an elongated body extending between a first side and a second side.

Description

Technical Field

[0001] This disclosure relates to a heated vehicle header. Background Technology

[0002] This section provides background information in connection with this disclosure, which is not necessarily prior art.

[0003] The upper body assembly of a vehicle, including the front and rear roof beams, provides structural support and mounting locations for other vehicle components. It is advantageous for vehicle components within structural assemblies to exhibit sufficient strength during normal use while simultaneously increasing occupant comfort. Summary of the Invention

[0004] This section provides a general overview of this disclosure and is not a full disclosure of its entire scope or all its features.

[0005] This disclosure relates to a composite vehicle roof beam configured at least partially to generate heat and a vehicle upper body assembly including the heated roof beam.

[0006] In various aspects, this disclosure provides a vehicle roof beam including an elongated body extending between a first side and a second side. The elongated body includes a polymer matrix, a plurality of fibers within the polymer matrix, and a heating element embedded in the polymer matrix. The heating element may be: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii). The heating element is configured to be coupled to an external circuit to generate heat within the elongated body.

[0007] In one aspect, the heating element includes at least a portion of the plurality of fibers, and the at least a portion of the plurality of fibers includes carbon fibers.

[0008] In one aspect, the heating element includes a discrete heating element. The discrete heating element includes a membrane. The membrane includes at least one layer.

[0009] In one aspect, the discrete heating element comprises a material selected from the group consisting of indium tin oxide (ITO), graphene, carbon nanotubes (CNTs), silver nanowires, or combinations thereof.

[0010] In one aspect, the plurality of fibers are selected from the group consisting of: carbon fiber, glass fiber, basalt fiber, aramid fiber, natural fiber, polyethylene fiber, polypropylene fiber, or any combination thereof.

[0011] In one respect, the multiple fibers include multilayer woven fibers.

[0012] In one aspect, the plurality of fibers comprises a plurality of filaments. The plurality of filaments cooperate to form a substantially polygonal shape.

[0013] In one aspect, the plurality of fibers includes a first fiber portion and a second fiber portion. The first fiber portion includes multiple layers of woven fibers. The second fiber portion includes a plurality of filaments that cooperate to form a substantially polygonal shape.

[0014] In one aspect, the vehicle component is a vehicle roof beam. The vehicle roof beam includes an elongated body extending between a first side and a second side.

[0015] In one aspect, the elongated body further includes an infrared (IR) reflector disposed adjacent to a first surface of the elongated body.

[0016] In one aspect, the elongated body further includes a plurality of conductive strips configured to electrically couple the heating element to the external circuitry. These conductive strips may include copper strips.

[0017] In one aspect, the plurality of conductive strips includes a first conductive strip and a second conductive strip. The first conductive strip is coupled to a first side, and the second conductive strip is coupled to a second side. The elongated body is configured to generate heat between the first side and the second side.

[0018] In one aspect, the heating element includes a first heating element and a second heating element. The plurality of strips includes a first conductive strip, a second conductive strip, a third conductive strip, and a fourth conductive strip. The elongated body also includes a first region, a second region, and a third region. The first region includes a first heating element extending between a first end and a second end. The first conductive strip is coupled to the first end, and the second conductive strip is coupled to the second end. The first region is configured to generate heat between the first end and the second end. The second region includes a second heating element extending between a third end and a fourth end. The third conductive strip is coupled to the third end, and the fourth conductive strip is coupled to the fourth end. The second region is configured to generate heat between the third end and the fourth end. A third region is disposed between the first region and the second region. The third region does not have a heating element.

[0019] In various aspects, this disclosure provides a vehicle roof beam including an elongated body extending between a first side and a second side. The elongated body includes a polymer matrix, a plurality of fibers in the polymer matrix, and a heating element embedded in the polymer matrix. The heating element is: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii). At least a portion of the elongated body is configured to be coupled to an external circuit to generate heat within the elongated body. At least a second portion of the elongated body has a transparency greater than or equal to approximately 0%.

[0020] In one aspect, the elongated body further includes a plurality of conductive strips configured to electrically couple the heating element to the external circuitry.

[0021] In one aspect, the heating element includes a first heating element and a second heating element. The plurality of conductive strips include a first conductive strip, a second conductive strip, a third conductive strip, and a fourth conductive strip. The elongated body includes a first region, a second region, and a third region. The first region includes a first heating element extending between a first end and a second end. The first conductive strip is coupled to the first end, and the second conductive strip is coupled to the second end. The first region is configured to generate heat between the first end and the second end. The second region includes a second heating element extending between a third end and a fourth end. The third conductive strip is coupled to the third end, and the fourth conductive strip is coupled to the fourth end. The second region is configured to generate heat between the third end and the fourth end. A third region is disposed between the first region and the second region. The third region does not have a heating element.

[0022] In one aspect, the first region and the second region have a transparency of more than or equal to about 0% and less than or equal to about 75%, and the third region has a transparency of more than or equal to about 0% and less than or equal to about 92%.

[0023] In one aspect, the heating element includes a discrete heating element. The discrete heating element includes a membrane. The membrane is: (i) at least partially transparent; (ii) at least partially opaque; or both (i) and (ii).

[0024] In various aspects, this disclosure provides a method of manufacturing a vehicle component. The method includes preparing a fiber mat comprising a first plurality of fibers and a second plurality of fibers. The first plurality of fibers comprises a first thermoplastic polymer. The second plurality of fibers comprises structural fibers, heating fibers, or both structural fibers and heating fibers. The method further includes forming a fiber mat assembly by sewing the fiber mat to a backing. The backing comprises a membrane. The membrane comprises a second thermoplastic polymer. The method further includes forming a composite material by consolidating the fiber mat assembly under heat and pressure. The method further includes forming the vehicle component by injecting a third thermoplastic polymer around at least a portion of the composite material.

[0025] In one aspect, the vehicle component is a roof beam. The first, second, and third thermoplastic polymers comprise polycarbonate. The second plurality of fibers comprise carbon fiber.

[0026] The present invention also includes the following technical solutions.

[0027] Option 1. A vehicle component, comprising:

[0028] Polymer matrix;

[0029] The plurality of fibers in the polymer matrix; and

[0030] A heating element embedded in the polymer matrix, the heating element being: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii), wherein the heating element is configured to be coupled to an external circuit to generate heat.

[0031] Option 2. The vehicle component according to Option 1, wherein:

[0032] The heating element includes at least a portion of the plurality of fibers, and

[0033] At least a portion of the plurality of fibers includes carbon fibers.

[0034] Option 3. The vehicle component according to Option 1, wherein the heating element includes the discrete heating element, the discrete heating element includes a membrane, and the membrane includes at least one layer.

[0035] Option 4. The vehicle component according to Option 3, wherein the discrete heating element comprises a material selected from the group consisting of indium tin oxide (ITO), graphene, carbon nanotubes (CNTs), silver nanowires, or combinations thereof.

[0036] Option 5. The vehicle component according to Option 1, wherein the plurality of fibers are selected from the group consisting of: carbon fiber, glass fiber, basalt fiber, aramid fiber, natural fiber, polyethylene fiber, polypropylene fiber, or any combination thereof.

[0037] Option 6. The vehicle component according to Option 1, wherein the plurality of fibers comprises multilayer woven fibers.

[0038] Option 7. The vehicle component according to Option 1, wherein the plurality of fibers comprise a plurality of filaments, and the plurality of filaments cooperate to form a substantially polygonal shape.

[0039] Option 8. The vehicle component according to Option 1, wherein:

[0040] The plurality of fibers includes a first portion and a second portion, the first portion comprising multilayer woven fibers, and

[0041] The second part includes multiple bundles of fibers that cooperate to form a substantially polygonal shape.

[0042] Option 9. The vehicle component according to Option 1, wherein the vehicle component is a roof beam, the roof beam comprising an elongated body extending between a first side and a second side.

[0043] Option 10. The vehicle component according to Option 9, wherein the elongated body further includes an infrared (IR) reflector disposed adjacent to a first surface of the elongated body.

[0044] Option 11. The vehicle component according to Option 9, wherein the elongated body further includes a plurality of conductive strips configured to electrically couple the heating element to the external circuit, the plurality of conductive strips including copper strips.

[0045] Option 12. The vehicle component according to Option 11, wherein:

[0046] The plurality of conductive strips includes a first conductive strip and a second conductive strip.

[0047] The first conductive strip is coupled to the first side, and the second conductive strip is coupled to the second side.

[0048] The elongated body is configured to generate heat between the first side and the second side.

[0049] Option 13. The vehicle component according to Option 11, wherein:

[0050] The heating element includes a first heating element and a second heating element.

[0051] The plurality of conductive strips includes a first conductive strip, a second conductive strip, a third conductive strip, and a fourth conductive strip, and

[0052] The elongated body also includes:

[0053] A first region includes a first heating element extending between a first end and a second end, a first conductive strip coupled to the first end, and a second conductive strip coupled to the second end, the first region being configured to generate heat between the first end and the second end.

[0054] A second region comprising a second heating element extending between a third end and a fourth end, the third conductive strip being coupled to the third end and the fourth conductive strip being coupled to the fourth end, the second region being configured to generate heat between the third end and the fourth end.

[0055] A third region is located between the first region and the second region, and the third region does not have the heating element.

[0056] Option 14. A vehicle roof beam, comprising:

[0057] An elongated body extending between a first side and a second side, the elongated body comprising:

[0058] polymer matrix,

[0059] The polymer matrix contains multiple fibers, and

[0060] A heating element embedded in the polymer matrix, the heating element being: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii), wherein,

[0061] At least a first portion of the elongated body is configured to be coupled to an external circuit to generate heat within the elongated body, and

[0062] At least the second portion of the elongated body has a transparency of about 0% or greater.

[0063] Option 15. The vehicle roof beam according to Option 14, wherein the elongated body further includes a plurality of conductive strips configured to electrically couple the heating element to the external circuit.

[0064] Option 16. The vehicle roof beam according to Option 15, wherein:

[0065] The heating element includes a first heating element and a second heating element.

[0066] The plurality of conductive strips includes a first conductive strip, a second conductive strip, a third conductive strip, and a fourth conductive strip, and

[0067] The elongated body includes:

[0068] A first region includes a first heating element extending between a first end and a second end, a first conductive strip coupled to the first end, and a second conductive strip coupled to the second end, the first region being configured to generate heat between the first end and the second end.

[0069] A second region comprising a second heating element extending between a third end and a fourth end, the third conductive strip being coupled to the third end and the fourth conductive strip being coupled to the fourth end, the second region being configured to generate heat between the third end and the fourth end.

[0070] A third region is located between the first region and the second region, wherein the third region does not have the heating element.

[0071] Option 17. The vehicle roof beam according to Option 16, wherein the first region and the second region have a transparency of greater than or equal to about 0% to less than or equal to about 75%, and the third region has a transparency of greater than or equal to about 0% to less than or equal to about 92%.

[0072] Option 18. The vehicle roof beam according to Option 14, wherein the heating element includes the discrete heating element, the discrete heating element including a membrane, the membrane being: (i) at least partially transparent; (ii) at least partially opaque; or both (i) and (ii).

[0073] Option 19. A method for manufacturing a vehicle component, the method comprising:

[0074] Prepare a fiber mat comprising a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers comprise a first thermoplastic polymer, and the second plurality of fibers comprise structural fibers, heating fibers, or both structural fibers and heating fibers;

[0075] A fiber pad assembly is formed by stitching the fiber pad to a backing, the backing comprising a membrane comprising a second thermoplastic polymer;

[0076] The composite material is formed by consolidating the fiber pad assembly under heat and pressure; and

[0077] The vehicle component is formed by injecting a third thermoplastic polymer around at least a portion of the composite material.

[0078] Option 20. The method according to Option 19, wherein,

[0079] The vehicle component is a roof beam.

[0080] The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer comprise polycarbonate, and

[0081] The second plurality of fibers includes carbon fibers.

[0082] Other applicable fields will become apparent from the description provided herein. The descriptions and specific examples in this invention are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0083] The accompanying drawings described herein are for illustrative purposes only, and not for all possible implementations, and are not intended to limit the scope of this disclosure.

[0084] Figure 1 It is a perspective view of the upper body structure of a vehicle, including the top beam, according to various aspects of this disclosure;

[0085] Figure 2 Based on all aspects of this disclosure Figure 1 A perspective view of the top beam;

[0086] Figure 3A This is a schematic diagram of the top beam according to various aspects of this disclosure;

[0087] Figure 3B yes Figure 3A A schematic cross-sectional view of the top beam;

[0088] Figure 4A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0089] Figure 4B yes Figure 4A A schematic cross-sectional view of the heated external portion of the top beam;

[0090] Figure 4C yes Figure 4A A schematic cross-sectional view of the unheated interior portion of the top beam;

[0091] Figure 5A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0092] Figure 5B yes Figure 5A A schematic cross-sectional view of the top beam;

[0093] Figure 6A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0094] Figure 6B yes Figure 6A A schematic cross-sectional view of the top beam;

[0095] Figure 7A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0096] Figure 7B yes Figure 7A A schematic cross-sectional view of the opaque outer portion of the top beam;

[0097] Figure 7C yes Figure 7A A schematic cross-sectional view of the transparent interior portion of the top beam;

[0098] Figure 7D yes Figure 7A A top view of the fiber structure of the transparent inner part of the top beam;

[0099] Figure 8A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0100] Figure 8B yes Figure 8A A schematic cross-sectional view of the heated, opaque portion of the top beam;

[0101] Figure 8C yes Figure 8A A schematic cross-sectional view of the unheated transparent portion of the top beam;

[0102] Figure 9A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0103] Figure 9B yes Figure 9A A schematic cross-sectional view of the heated, opaque portion of the top beam;

[0104] Figure 9C yes Figure 9A A schematic cross-sectional view of the unheated transparent portion of the top beam;

[0105] Figure 10A This is a schematic diagram of another supporting beam according to various aspects of this disclosure;

[0106] Figure 10B yes Figure 10A A schematic cross-sectional view of the heated, opaque portion of the top beam;

[0107] Figure 10C yes Figure 10A A schematic cross-sectional view of the unheated transparent portion of the top beam;

[0108] Figure 11A These are thermal images of the heated portion of the top beam according to various aspects of this disclosure;

[0109] Figure 11B yes Figure 11A Photos of multiple fibers in the top beam;

[0110] Figure 11C When a current of 2 amperes is applied to Figure 11A The graph showing the relationship between temperature and time, and voltage and time when the top beam is in operation;

[0111] Figure 12A These are photographs of the transparent portion of the heated section of the top beam according to various aspects of this disclosure;

[0112] Figure 12B yes Figure 12A Thermal image of the top beam section;

[0113] Figure 12C When a current of 2 amperes is applied to Figure 12A A graph showing the relationship between temperature and time in a portion of the top beam;

[0114] Figure 12DWhen a current of 1.6 amps is applied to Figure 12A A graph showing the relationship between temperature and time in a portion of the top beam;

[0115] Figure 12E yes Figure 12B thermal images and Figure 12B Line scan of thermal images; and

[0116] Figure 13 It is a flowchart depicting a method for manufacturing vehicle parts according to various aspects of this disclosure.

[0117] The corresponding reference numerals in the accompanying drawings indicate the corresponding parts in several views. Detailed Implementation

[0118] Exemplary embodiments are provided to make this disclosure thorough and to fully communicate its scope to those skilled in the art. Numerous specific details, such as examples of particular compositions, components, apparatuses, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that the specific details are not required, that exemplary embodiments may be implemented in many different forms, and none of them should be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0119] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “an” may also include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and thus specify the presence of the stated features, elements, compositions, steps, integers, operations, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Although the open-ended term “comprising” should be understood as a non-limiting term used to describe and claim the various embodiments set forth herein, in some aspects, the term may alternatively be understood as a more restrictive and binding term, such as “consisting of” or “substantially consisting of.” Therefore, for any given embodiment recounting compositions, materials, components, elements, features, integers, operations, and / or process steps, this disclosure also specifically includes embodiments consisting of or substantially consisting of those recited compositions, materials, components, elements, features, integers, operations, and / or process steps. In the case of “consisting of…”, the alternative embodiments do not include any additional compositions, materials, components, elements, features, integers, operations and / or process steps, while in the case of “consisting substantially of…”, any additional compositions, materials, components, elements, features, integers, operations and / or process steps that substantially affect the basic and novel characteristics are excluded from such embodiments, but any compositions, materials, components, elements, features, integers, operations and / or process steps that do not substantially affect the basic and novel characteristics may be included in the embodiments.

[0120] Unless explicitly indicated as to the order of execution, no method steps, procedures, and operations described herein should be construed as requiring them to be performed in the specific order discussed or illustrated. It should also be understood that additional or alternative steps may be used unless otherwise stated.

[0121] When a component, element, or layer is referred to as being “on,” “joined to,” “connected to,” or “coupled to” another component or layer, it may be directly on, joined to, or coupled to that other component, element, or layer, or there may be intermediate components or layers. Conversely, when an element is referred to as being “directly on,” “directly joined to,” “directly connected to,” or “directly coupled to” another component or layer, there may be no intermediate components or layers. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0122] Although the terms “first,” “second,” “third,” etc., may be used herein to describe various steps, elements, components, regions, layers, and / or sections, these steps, elements, components, regions, layers, and / or sections should not be limited by these terms unless otherwise stated. These terms are used only to distinguish one step, element, component, region, layer, or section from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms, when used herein, do not imply order or sequence. Therefore, without departing from the teachings of exemplary embodiments, the first step, element, component, region, layer, or section discussed below may be referred to as the second step, element, component, region, layer, or section.

[0123] Spatial or temporal relative terms, such as “before,” “after,” “inside,” “outside,” “below,” “below,” “down,” “above,” “up,” etc., are used herein for ease of description to describe the relationship between one element or feature and another element or feature as shown in the figures. Spatial or temporal relative terms, in addition to the orientations depicted in the figures, may also be intended to encompass different orientations of the apparatus or system in use or operation.

[0124] Throughout this disclosure, numerical values ​​represent approximate measurements or limitations of a range to cover minute deviations from a given value and embodiments having approximately the mentioned value, as well as embodiments having exactly the mentioned value. Except for the working examples provided at the end of the detailed description, numerical values ​​of all parameters (e.g., quantities or states) in this specification (including the appended claims) should be understood to be modified in all cases by the term "approximately," regardless of whether "approximately" actually precedes the numerical value. "Approximately" indicates that the numerical value allows for some slight imprecision (accuracy by some method of approximating the numerical value; approximately or reasonably close to the numerical value; almost). If the imprecision provided by "approximately" is not understood in this common sense in the art, then "approximately" as used herein at least indicates variations that may arise from common methods of measuring and using these parameters. For example, "approximately" can include variations such as: less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in some respects optionally less than or equal to 0.1%.

[0125] In addition, the disclosure of a range includes the disclosure of all values ​​as well as the disclosure of further subdivisions of the range throughout the entire range, including the endpoints and subranges given for these ranges.

[0126] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

[0127] Structural components in a vehicle provide structural support and / or mounting locations for other vehicle parts. Structural components for the upper body structure may include multiple upper body parts, such as a front roof beam, a rear roof beam, a roof, a driver's side roof longitudinal beam, a passenger's side roof longitudinal beam, and one or more pairs of structural struts. The roof may extend rearward from the front roof beam within the vehicle and connect the driver's side roof longitudinal beam to the passenger's side roof longitudinal beam. The front roof beam connects the driver's side roof longitudinal beam to the passenger's side roof longitudinal beam. The front roof beam supports both the roof and the windshield and connects the roof to the windshield. High stiffness and strength in the upper body structure is advantageous in localized areas near the roof longitudinal beams and structural struts, particularly near the junctions between the roof beams and roof longitudinal beams and between the roof and roof longitudinal beams.

[0128] Upper body components can be constructed from a variety of materials. For example, certain parts of the roof beam are typically opaque. For instance, structural components including the vehicle roof beam can be constructed from metals such as steel. In another example, the vehicle roof beam can be constructed from composite materials, such as fiber-reinforced composites and / or laminated composites.

[0129] Vehicles are typically equipped with heating systems to heat various vehicle components and / or the passenger compartment. For example, many vehicles include heated seats, heated steering wheels, heated rear windows, and passenger compartment heating and cooling systems. Upper body components, such as the roof beams, are typically not heated or cooled.

[0130] In various aspects, this disclosure provides a roof beam component for a vehicle upper body structure. The roof beam may be a front vehicle roof beam or a rear vehicle roof beam. The roof beam may be configured to provide structural support, occupant comfort and / or occupant visibility, and / or to shield occupants from rain, snow, ultraviolet (UV) light, infrared (IR) wavelengths and / or other elements. The roof beam may be constructed of or comprise a fiber-reinforced composite material. The fiber-reinforced composite material may include a polymer and a plurality of fibers. The roof beam utilizes integrated heating elements configured to heat the roof beam (e.g., by Joule heating and / or radiant heating) for thermal compensation. As used herein, “configured to heat” means that at least a portion of the roof beam is configured to generate heat. In some aspects, the roof beam may be configured to conduct heat toward a windshield to aid in the defrosting process. In some aspects, the roof beam may be configured to heat the passenger compartment and / or the windshield. The roof beam may be configured to be heated by various heating elements such as thermally conductive structural fibers and / or membranes. In some aspects, at least a portion of the roof beam is at least partially transparent. As used in this article, “transparent” means that at least a portion of the top beam has a transparency greater than 0%.

[0131] refer to Figure 1The present disclosure provides an upper body structure 100 for a vehicle according to various aspects thereof. The upper body structure 100 may at least partially define and surround the upper periphery of a vehicle passenger compartment 102. The upper body structure 100 includes a pair of laterally spaced A-pillars 104 and a pair of laterally spaced roof longitudinal beams 106. The pair of roof longitudinal beams 106 may include a driver-side roof longitudinal beam 108 and a passenger-side roof longitudinal beam 110. The roof longitudinal beams 106 may be fixed to or integrally formed with the respective A-pillars 104. The roof longitudinal beams 106 may extend substantially parallel to the longitudinal or front-rear axis 112 of the vehicle. Alternative vehicle architectures may include additional structural struts (not shown), such as a pair of B-pillars, a pair of C-pillars, and / or a pair of D-pillars. The struts including the A-pillars 104 may extend substantially perpendicularly from the roof longitudinal beams 106 and may be configured to connect the upper body structure 100 to a lower body structure (not shown), thereby further defining the passenger compartment 102.

[0132] The roof 120 may be at least partially disposed between the roof longitudinal beams 106. The roof 120 may have a generally rectangular shape. The sides of the roof 120 may extend substantially parallel to the lateral or transverse axis 122 of the vehicle and substantially parallel to the front and rear axis 112 of the vehicle.

[0133] A front roof beam 130 (also referred to as "roof beam 130") is at least partially disposed between the roof longitudinal beams 106. The roof beam 130 may extend substantially orthogonally to the roof longitudinal beams 106. The roof beam 130 may be configured to couple the driver-side roof longitudinal beam 108 to the passenger-side roof longitudinal beam 110. The roof beam 130 may be coupled adjacent to the A-pillar 104 to the roof longitudinal beams 108, 110. The front roof beam 130 may be configured to couple the roof 120 to the windshield 134. As will be described in more detail below, the front roof beam 130 is configured to generate heat.

[0134] The rear roof beam 132 may be at least partially disposed between the roof longitudinal beams 106. The rear roof beam 132 may extend substantially orthogonally to the roof longitudinal beams 106. The rear roof beam 132 may be configured to couple to the roof longitudinal beams 106 adjacent to the rear end of the upper body structure 100.

[0135] In some respects, such as Figure 1 As shown, the upper body structure 100 does not have additional cross-car reinforcements. However, in some other respects, the upper body structure 100 may optionally include one or more cross-car reinforcements (not shown). These cross-car reinforcements may extend substantially orthogonally between the roof longitudinal beams 106. The cross-car reinforcements may be longitudinally spaced across the front and rear axles 112 as needed to provide structural support and / or strength to the upper body structure 100.

[0136] refer to Figure 2The roof beam 130 includes an elongated body 140. The elongated body 140 extends between a first side 142 and a second side 144 (also referred to as "sides 142, 144"). Sides 142, 144 may be configured to be correspondingly coupled to the passenger-side roof longitudinal beam 110. Figure 1 ) and driver's side roof longitudinal beam 108 ( Figure 1 In some respects, the top beam 130 includes a first or top surface 146 and a second or bottom surface 148.

[0137] Windshield 134 ( Figure 1 The top beam 130 may have a curvature (not shown) according to a desired curvature to meet the vehicle's architectural design. The top beam 130 may have a curvature similar to that of the windshield 134. The top beam 130 may have different geometries (e.g., shape and / or curvature), features (e.g., outer edges and / or formations), and constructions as needed to meet the desired mechanical performance and / or aesthetic characteristics of the upper body structure 100.

[0138] In various aspects, the stiffness and strength of the top beam 130 achieve the desired mechanical properties of the upper body structure 100. In some aspects, the top beam 130 may be without additional reinforcing members. In some aspects, the local tensile strength (tensile strength in at least one region of the top beam) of the top beam 130 may be greater than or equal to about 20 MPa to greater than or equal to about 2400 MPa. In some aspects, the tensile modulus of the upper body components may be greater than or equal to about 300 GPa to greater than or equal to 500 GPa.

[0139] In some respects, the top beam 130 can be substantially opaque, as accompanied by the following: Figure 3A-6B As described in the discussion. In some other respects, a portion of the top beam 130 may be substantially opaque. In some respects, the top beam 130 may be at least partially transparent (also referred to as a "transparent top beam"), as accompanied by the following. Figure 7A-10C As stated in the discussion.

[0140] The top beam 130 according to various aspects of this disclosure may include a polymer and a plurality of fibers. In some aspects, the top beam 130 is a fiber-reinforced composite material. Fiber-reinforced composite top beams according to various aspects of this disclosure may be lighter than metal top beam components of the same size. Such lighter upper body components can improve vehicle fuel efficiency and / or battery range.

[0141] The polymer may be a thermosetting polymer or a thermoplastic polymer. In some aspects, the polymer may include a substantially opaque thermosetting polymer selected from the group consisting of: epoxy resins, polyurethanes (PUR), vinyl esters, polyacrylates (acrylic acid), polyimide (PI), bismaleimide (BMI), phenolic resins (PF), copolymers thereof, and combinations thereof. In some aspects, when fiber-free, the polymer may include a substantially transparent thermosetting polymer. A substantially transparent thermosetting polymer is selected from the group consisting of: epoxy resins, PUR, polyacrylates (acrylic acid), PI, PF, copolymers thereof, and combinations thereof. In some aspects, the polymer may be a substantially opaque thermoplastic polymer selected from the group consisting of: polycarbonate (PC), polymethyl methacrylate, thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polyamide (PA) (e.g., nylon 6, nylon 66, nylon 12, PA 11, PA 10T / 10I / 10-12), polyethyleneimine (PEI), polyamide-imide (PAI), polyetheretherketone (PEEK), polyetherketone (PEK), polyphenylene sulfide (PPS), polypropylene (PP), polycarbonate / acrylonitrile butadiene-styrene (PC / ABS), high-density polyethylene (HDPE), poly(methyl methacrylate) (PMMA), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), copolymers thereof, and combinations thereof. In some aspects, when free of fibers, the polymer may be a substantially transparent polymer. In some aspects, the substantially transparent thermoplastic polymer may be selected from the group consisting of: PC, PMMA, TPU, PET, PA (e.g., PA 11, PA 10T / 10I / 10-12), copolymers thereof, and combinations thereof. In some aspects, the top beam 130 may include more than one polymer. In some aspects, the top beam 130 may include both: a substantially transparent polymer, for example in areas of higher transparency; and a substantially opaque polymer, for example in areas of lower transparency or opacity.

[0142] In some aspects, the polymer may include fillers. In some aspects, the polymer may be a colored polymer. In some aspects, the colored polymer includes a colored pigment in an amount required to satisfy the desired aesthetic and / or transparency characteristics of the top beam 130. Any of the above-mentioned polymers may include fillers, such as pigments. As an example, the colored polymer may be selected from the group consisting of PC, PMMA, copolymers thereof, and combinations thereof. In some aspects, the transparent polymer may be colored to reduce the amount of light passing through the top beam, such as sunlight that heats the passenger compartment.

[0143] In some respects, the plurality of fibers (also referred to as “fibers”) may have lengths and / or configurations that satisfy the desired strength, stiffness, and conductivity characteristics of the top beam 130. The top beam 130 may optionally include more than one fiber configuration to achieve the desired mechanical strength and / or stiffness.

[0144] In some respects, the plurality of fibers includes heating fibers (also referred to as “heating fibers”). The heating fibers may be structural heating fibers. As used herein, a “structural heating fiber” is a fiber having sufficient strength, stiffness, and conductivity to achieve the heating characteristics of the top beam 130. Suitable structural heating fibers may include carbon fibers (e.g., carbon black, carbon nanotubes, talc, fibers derived from polyacrylonitrile and / or pitch precursors), or other fibers suitable for conducting and / or generating heat through the elongated body 140 of the top beam 130.

[0145] In some respects, these multiple fibers include structural fibers. As used herein, a “structural fiber” is a fiber that exhibits desired strength and stiffness properties. Structural fibers may be selected from the group consisting of: carbon fibers, glass fibers (e.g., E-glass, glass fiber, quartz), natural fibers (e.g., flax, ramie, hemp, spider silk, cellulose, cotton), basalt fibers, aramid fibers (e.g., KEVLAR®, polybenzodioxazole (PBO)), polyethylene fibers (e.g., high-strength ultra-high molecular weight (UHMW) polyethylene), polypropylene fibers (e.g., high-strength polypropylene), and combinations thereof.

[0146] In some respects, the structural fibers include thermally insulating fibers with relatively low thermal conductivity. The thermally insulating fibers can be configured to reduce heat transfer through the elongated body 140 of the top beam 130. The thermally insulating fibers can be selected from the group consisting of: glass fibers (e.g., E-glass, glass fiber, quartz), natural fibers (e.g., flax, ramie, hemp, spider silk, cellulose, cotton), basalt fibers, aramid fibers (e.g., KEVLAR®, polybenzo[a]benzo[a]oxazole (PBO)), polyethylene fibers (e.g., high-strength ultra-high molecular weight (UHMW) polyethylene), polypropylene fibers (e.g., high-strength polypropylene), and combinations thereof. The heating fibers, structural fibers, and thermally insulating fibers can be used in combination or individually, and configured as needed (e.g., included in a certain volume percentage and / or oriented) to meet the desired structural and thermal characteristics of the top beam 130.

[0147] Fibers (i.e., heating fibers, structural fibers, insulating fibers, and combinations thereof) can be manufactured as woven fabrics, continuous random fabrics, discontinuous random fibers, chopped strand random fabrics, continuous unidirectional ply layers, oriented chopped strand layers, braided fabrics, and any combination thereof. In some respects, such as Figure 3A-6BAs described in 8A-10C, all fibers can be woven into fabrics. In some respects, the fibers in woven fabrics extend in both a first or vertical direction and a second or horizontal direction.

[0148] In some respects, heated fibers can be woven together with thermoplastic fibers and sewn into a membrane. In one example, carbon fibers are mixed with thermoplastic polycarbonate fibers. These fibers can be sewn into a membrane (e.g., a polycarbonate membrane).

[0149] In some aspects, at least a portion of the fibers may be aligned and positioned (e.g., via a belt) in a tow-line geometry. In some aspects, this geometry may be substantially polygonal. In some aspects, this geometry may be hexagonal (e.g., see...). Figure 7A and 7D However, other shapes and geometries are also possible. In some respects, the top beam 130 may comprise both fibers embroidered into a woven fabric and fibers aligned in bundles (see, for example, [link to relevant documentation]). Figure 7A In some aspects, the top beam 130 comprises multiple layers of fibers, such as multiple layers of woven fabric. In some aspects, the fiber configuration is substantially uniform across the elongated body 140. In some other aspects, the top beam 130 may comprise multiple regions or sections. The fiber configuration of each region or section may be the same or different, such that the fiber configuration may vary across the upper body components.

[0150] In some aspects, the top beam 130 may include a total amount of fibers ranging from greater than or equal to 5% by volume to less than or equal to about 70% by volume. In some aspects, such as when substantially the entire top beam is configured to generate heat and / or substantially the entire top beam is opaque, the volume percentage or volume fraction of the fibers may be substantially uniform across the elongated body 140 of the top beam 130. In some other aspects, the top beam 130 may include multiple regions or sections. The volume percentage of fibers in each region or section may be the same or different, such that the volume percentage of fibers may vary across the top beam 130. In some aspects, regions with a relatively high volume percentage of fibers may have relatively higher strength and / or stiffness compared to regions with a lower volume percentage of fibers. In some aspects, regions including a higher volume percentage of fibers may include a quantity of fibers greater than or equal to 40% by volume. In some aspects, regions including a higher volume percentage of fibers may include a quantity of fibers greater than or equal to 50% by volume. In some aspects, regions with a relatively low volume percentage of fibers may have relatively lower strength and / or stiffness compared to regions with a higher volume percentage of fibers. In some respects, regions with a relatively low volume percentage of fibers may include a fiber amount of less than or equal to 20 volume percentages. In some respects, the strength of each region or section may be the same or different, such that the strength of the top beam 130 may vary across the elongated body 140.

[0151] In various aspects, the strength, conductivity (i.e., thermal properties), and transparency of the top beam 130 can be customized through polymer selection, fiber selection, and / or fiber configuration. In some aspects, the thermal properties of the top beam 130 can be customized by including fibers with a desired resistivity. In some aspects, each region or section may include the same polymer and / or fibers. In some other aspects, each region or section may include different polymers and / or fibers. In some aspects, a region or section may include a substantially fiber-free polymer (e.g., when low thermal properties and / or high transparency are desired). The substantially fiber-free polymer may be the same as or different from the polymer in the region including both polymer and fibers. Any combination of polymers including any fiber combination can be utilized and constructed to provide the desired strength, conductivity, and transparency properties of the top beam.

[0152] According to various aspects of this disclosure, at least a portion of the top beam 130 is configured to generate heat (i.e., one or more regions of the top beam are configured to generate heat). In some aspects, the top beam 130 also includes heating elements (e.g., fibers and / or different heating elements) embedded in a polymer matrix. In some aspects, the top beam 130 may include multiple regions with customized heating characteristics. For example, some regions intended to provide heat to the passenger compartment may include heating elements. Regions not intended to provide heat to the passenger compartment may not have heating elements.

[0153] In some respects, the heating element may include discrete heating elements, such as heating films, as follows: Figures 6A-6B As described in more detail in the discussions of 9A-9B and 10A-10B. In some aspects, the heating film includes a conductive material. The heating film may be defined in a substantially planar form, such as a single-layer sheet or a multi-layer sheet. The heating film may include a sheet consisting substantially of a conductive material or a sheet including a conductive material dispersed in and / or embedded in a polymer.

[0154] The polymer of the heating film (i.e., the polymer of the discrete heating element) may be the same as or different from the polymer of the top beam 130. In some aspects, the heating film comprises a polymer nanocomposite film. In some aspects, the polymer nanocomposite film is a commercially available polymer nanocomposite film. The heating film may comprise materials selected from the group consisting of: indium tin oxide (ITO) (e.g., ITO sheets), carbon nanotubes (e.g., as a monolayer or embedded in a polymer), graphene (e.g., sheets or layers and / or embedded in a polymer), silver (e.g., silver nanowires, sheets or layers, and / or embedded in a polymer) or combinations thereof.

[0155] In some aspects, the heating element may comprise a monolayer having a thickness greater than or equal to about 0.1 nanometers (nm) to less than or equal to about 1 millimeter (mm). In some aspects, for example, when the heating element comprises a monolayer of ITO, the heating element may have a thickness less than or equal to 1 mm. In some aspects, heating elements comprising ITO have a thickness greater than or equal to about 10 nm to less than or equal to about 500 nm. In some aspects, for example, when the heating element comprises a monolayer of graphene, the heating element may have a thickness greater than or equal to about 0.3 nm to less than or equal to about 0.4 nm. In some aspects, for example, when the heating element comprises graphene embedded in a polymer (e.g., the graphene is embedded as a sheet or strip, particle, and / or flake), the heating element may have a thickness greater than or equal to about 100 nm to less than or equal to about 1 mm. In some aspects, for example, when the heating element comprises carbon nanotubes and / or silver nanowires embedded in a polymer, the heating element may have a thickness greater than or equal to about 100 nm to less than or equal to about 1 mm. In some aspects, the top beam 130 may include a heating element comprising a multilayer film. In some aspects, the heating element comprising a multilayer film may have a thickness greater than or equal to about 0.01 micrometers (μm) to less than or equal to about 100 μm.

[0156] In some aspects, the top beam 130 may include more than one heating film, such as two or more heating films, optionally three or more heating films, optionally five or more heating films, optionally seven or more heating films, or optionally ten or more heating films. In some aspects, the heating film may be substantially opaque. In some other aspects, the heating film may be substantially transparent.

[0157] In some respects, the heating element includes at least a portion of the plurality of fibers (e.g., when the plurality of fibers include heating fibers with conductive properties, such as carbon fibers), as will be described below. Figure 3A-5B As described in more detail in 7A-8B and 10A-10C. That is, all or part of the plurality of fibers may be configured to conduct and / or generate heat. In some aspects, the heating element may include a combination of both discrete heating elements and at least a portion of the plurality of fibers, as described below. Figures 10A-10C This will be described in more detail in the discussion. In some respects, the heating element is configured to be coupled to an external circuit to generate heat in at least a portion of the top beam 130.

[0158] In some respects, the top beam 130 includes multiple tapes (also called "belts"), as follows. Figure 3A-10CThis is described in more detail in the discussion. In some aspects, these strips may be fiber-reinforced strips, configured to structurally reinforce the fibers to achieve the desired strength and / or stiffness characteristics of the top beam 130. In some aspects, these strips may include conductive tape. The conductive tape may be configured to electrically couple the heating element to an external circuit. The conductive tape may include a metal foil and an adhesive layer directly coupled to the metal foil. These strips may include copper strips, other suitable strips with high conductivity, or combinations thereof.

[0159] In some aspects, the top beam 130 also includes conductive paste, either alone or in combination with conductive strips. In some aspects, the conductive paste may further reinforce the structural fibers. In some aspects, the conductive paste may cooperate with the conductive strips to electrically couple the heating element to an external circuit.

[0160] In some respects, the top beam 130 may include an infrared (IR) reflector, as follows: Figure 3A-10C As described in more detail in the discussion. The IR reflector may be at least partially disposed on the first surface 146 of the top beam 130 (e.g., see...). Figures 3A-3B (IR reflector 312). The IR reflector may be configured to prevent IR wavelengths (e.g., IR light from the sun) from passing through the windshield 134 and reaching the body 140 of the top beam 130. In some aspects, the IR reflector may comprise a material selected from the group consisting of: chrome plating, aluminum foil, multilayer films, or combinations thereof. In some aspects, the IR reflector may have a thickness greater than or equal to about 100 nm and less than or equal to about 5 μm. In some aspects, the top beam 130 may comprise more than one IR reflector, such as greater than or equal to two IR reflectors, optionally greater than or equal to three IR reflectors, optionally greater than or equal to five IR reflectors, optionally greater than or equal to seven IR reflectors, or optionally greater than or equal to ten IR reflectors. In some other aspects, the top beam 130 may have no IR reflector.

[0161] In various aspects, when power (e.g., electric current) is applied from an external circuit, the current flows through the heating element. The current undergoes resistance from the heating element. As the current flows through the heating element, the resistance in the heating element generates heat. In the presence of current, a higher resistance level generates more heat. As the heat in the body 140 increases, the material temperature of the body 140 increases, and the body 140 of the top beam 130 generates heat. The temperature of the top beam 130 generally increases as the power is applied for an extended period. In some aspects, at least a portion of the top beam 130 may be configured to be heated to a temperature greater than or equal to about 40℉ to less than or equal to about 75℉. In some aspects, the top beam may be configured to be heated to a temperature greater than or equal to about 45℉, optionally greater than or equal to about 50℉, optionally greater than or equal to about 55℉, optionally greater than or equal to about 60℉, optionally greater than or equal to about 65℉, or optionally greater than or equal to about 70℉. In some respects, the top beam may be configured to be heated to a temperature less than or equal to about 65℉, optionally less than or equal to about 60℉, optionally less than or equal to about 55℉, optionally less than or equal to about 50℉, or optionally less than or equal to about 45℉.

[0162] The top beam according to various aspects of this disclosure can be configured to be heated by heating fibers over its substantially entire body. Reference Figures 3A-3B The present disclosure provides a top beam 300 for an upper body structure according to various aspects thereof, which, apart from the top beam 300, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 300 may be connected with... Figure 1-2 The top beam 130 is identical. The top beam 300 includes an elongated body 302 (also referred to as "body 302"). The body 302 extends between a first side 304 and a second side 306 (also referred to as "sides 304, 306") opposite to the first side 304. The top beam 300 includes a first surface 308 (e.g., a top surface) and a second surface 310 (e.g., a bottom surface). In some aspects, such as Figure 3B As best shown, the IR reflector 312 is disposed adjacent to the first surface 308.

[0163] In some respects, the top beam 300 includes polymer 313 ( Figure 3B Polymer 313 may include an opaque polymer. Polymer 313 may be distributed throughout the body 302 of the top beam 300.

[0164] In some respects, the top beam 300 includes multiple layers 314 ( Figure 3BIn some respects, all or part of the layers may be integrally formed. In some respects, all or part of the layers may be integrally formed with the same polymer 313. The top beam 300 may include a first portion 316 of layer 314 and a second portion 318 of layer 314. Each layer 314 includes one of a plurality of fibers 320 ( Figure 3B In some aspects, fiber 320 may include heating fibers. In some aspects, the heating fibers may be structural heating fibers that, in addition to being configured to conduct and / or generate heat, also provide structural support. In some aspects, at least a portion of the heating fibers is configured as a heating element of the top beam 300. In one example, all fibers are structural heating fibers, such as conductive carbon fibers. In another example, conductive heating fibers are woven together with non-conductive structural fibers.

[0165] In some respects, in each layer 314, fibers 320 may be arranged in a single layer or multiple layers. As shown, fibers 320 may be uniformly distributed across the body 302, or alternatively, non-uniformly distributed depending on the desired strength and / or heating characteristics of the top beam 300.

[0166] In some aspects, the top beam 300 includes multiple strips, including a first strip 322 and a second strip 324. Each of the strips 322 and 324 may include a metal foil 326 (e.g., copper foil). In some aspects, an adhesive 328 is directly coupled to the metal foil and is configured to couple the strips 322 and 324 to the top beam 300. In some aspects, the strips 322 and 324 have an average thickness greater than or equal to about 100 μm, for example greater than or equal to about 150 μm, or optionally greater than or equal to about 200 μm.

[0167] In some respects, bands 322 and 324 are at least partially disposed between the first portion 316 of layer 314 and the second portion 318 of layer 314, such as Figure 3B As shown in the diagram. In some other aspects, strips 322, 324 may be at least partially disposed in the first portion 316 of layer 314 (e.g., relatively closer to the first surface 308). In some other aspects, strips 322, 324 may be at least partially disposed in the second portion 318 of layer 314 (e.g., relatively closer to the second surface 310). In some aspects, top beam 300 may include additional strips such that the strips are disposed in both the first portion 316 and the second portion 318 of layer 314. The placement of strips 322, 324 in top beam 300 may be modified to meet desired structural and bending characteristics of top beam 300.

[0168] In some aspects, a first strip 322 is disposed in a top beam 300 adjacent to a first side 304. In some aspects, a second strip 324 is disposed in a top beam 300 adjacent to a second side 306. In some aspects, strips 322 and 324 are embedded in the top beam 300 and are disposed at least partially at a distance between layers 314, which may be greater than or equal to about 1 millimeter (mm) from the respective sides 304 and 306.

[0169] In some respects, strips 322 and 324 are configured to electrically couple fiber 320 to external circuit 329. When current is applied to external circuit 329, fiber 320 creates a resistive conductive path (e.g., current flow) between first strip 322 and second strip 324. This resistance generates heat 330. Figure 3A The heat generated is due to the thermal energy of the fiber 320. In other words, when external power is applied to the top beam 300 at the belts 322 and 324, the resistance of the fiber 320 generates heat 330 along the body 302 between the first belt 322 and the second belt 324. In some aspects, the top beam 300 is configured to generate heat 330 through the body 302 between the first side 304 and the second side 306 (i.e., heat is generated substantially over the entire top beam). The local area and amount of heat generated can be customized by modifying the belt configuration (e.g., the placement of the belts) and the heating element configuration (e.g., the volume, resistance, and / or conductivity of the structural heating fibers) to achieve the desired structural and heating characteristics of the top beam 300.

[0170] The top beam according to various aspects of this disclosure can be configured to be heated across one or more regions or portions of its body by heating fibers, said one or more regions or portions being smaller than the entire body. Reference Figures 4A-4C The present disclosure provides a top beam 400 for an upper body structure according to various aspects thereof, which, apart from the top beam 400, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 400 may be connected with... Figures 3A-3B The top beam 300 is the same. The top beam 400 includes an elongated body 402. The elongated body 402 extends between a first side 404 and a second side 406 (also referred to as "sides 404, 406") opposite to the first side 404. The top beam 400 includes a first surface 408 and a second surface 410. In some aspects, such as Figure 4B As best shown in –4C, the IR reflector 412 is disposed adjacent to the first surface 408.

[0171] In some respects, the top beam 400 may include one or more regions or portions, such as a first outer region 414 and a second outer region 416. Figure 4A(Also referred to as "outer regions 414, 416"). Each of the outer regions 414, 416 may include a first end or outer end 420 and a second end or inner end 422. The first end 420 of each of the outer regions 414, 416 may correspondingly include a first side 404 and a second side 406. In some aspects, the top beam 400 may include an inner region 428 disposed between the second end 422 of the first outer region 414 and the second end 422 of the second outer region 416.

[0172] In some respects, the top beam 400 includes polymer 429 ( Figure 4B –4C). Polymer 429 may include an opaque polymer. In some aspects, outer regions 414, 416 and inner region 428 may be integrally formed using the same polymer 429. In some other aspects, polymer 429 may include more than one polymer, such as a first polymer in outer regions 414, 416 and a second polymer in inner region 428.

[0173] In some respects, the top beam 400 comprises multiple layers 430 ( Figure 4B-4C The top beam 400 may include a first portion 432 of layer 430 and a second portion 434 of layer 430. In some aspects, all or part of the layers may be integrally formed. In some aspects, all or part of the layers may be integrally formed with the same polymer 429. Each layer 430 includes one of a plurality of fibers 440 ( Figure 4B –4C). Fiber 440 can be combined with… Figures 3A-3B The fibers are the same as or similar to 320.

[0174] In some respects, the top beam 400 comprises multiple bands, including band 460, band 462, band 464, and band 466 (also collectively referred to as "bands 460, 462, 464, and 466"). Unless otherwise stated below, bands 460, 462, 464, and 466 may be used interchangeably with... Figures 3A-3B The bands 322 and 324 are the same or similar. In some respects, such as Figure 4B As shown, the first outer region 414 includes a first tape 460 disposed adjacent to a first end 420 of the first outer region 414 in the top beam 400 and a second tape 462 disposed adjacent to a second end 422 of the first outer region 414 in the top beam 400. A third tape 464 may be disposed adjacent to the first end 420 of the second outer region 416 in the top beam 400, and a fourth tape 466 may be disposed adjacent to the second end 422 of the second outer region 416 in the top beam 400. In some aspects, such as Figure 4C As best shown, the internal region 428 can be essentially without bands.

[0175] The first external region 414 may be configured to generate heat 468 between the first band 460 and the second band 462 when current is applied to the first external circuit 470. Figure 4A Similarly, the second outer region 416 may be configured to generate heat 468 between the third strip 464 and the fourth strip 466 when current is applied to the second outer circuit 472. In some respects, the inner region 428 is not configured to generate heat. Although the top beam 400 is configured to generate heat 468 in the outer regions 414, 416, other top beams may include different or additional regions configured to generate heat, for example, through different or additional strip placement, heating fiber inclusion, and / or external circuit connection.

[0176] A top beam according to various aspects of this disclosure, comprising heated fibers and unheated structural fibers, can be configured such that the heated fibers are heated over substantially the entire body of the beam. Reference Figures 5A-5B The present disclosure provides a top beam 500 for an upper body structure according to various aspects thereof, which, apart from the top beam 500, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 500 may be connected with... Figures 3A-3B The top beam 300 is identical. The top beam 500 includes an elongated body 502. The elongated body 502 extends between a first side 504 and a second side 506 (also referred to as "sides 504, 506") opposite to the first side. The top beam 500 includes a first surface 508 and a second surface 510. In some aspects, such as Figure 5B As best shown, the IR reflector 512 is disposed adjacent to the first surface 508.

[0177] In some respects, the top beam 500 includes polymer 513 ( Figure 5B Polymer 513 may include an opaque polymer. Polymer 513 may be distributed throughout the body 502 of the top beam 500.

[0178] In some respects, the top beam 500 includes multiple layers 514 ( Figure 5B The top beam 500 may include a first portion 516, a second portion 517, a third portion 518, and a fourth portion 519 of layer 514. In some aspects, all or part of layer 514 may be integrally formed. In some aspects, all or part of layer 514 may be integrally formed with the same polymer 513. Each layer 514 includes one of a plurality of fibers 520 ( Figure 5B Fiber 520 may include a first portion 522 and a second portion 524. In some aspects, the first portion 522 of fiber 520 may be... Figures 3A-3BThe fibers 320 are the same as or similar to the fibers 520. A first portion 522 of fiber 520 may be configured as a heating element. In some aspects, a second portion 524 of fiber 520 may include structural fibers. In some aspects, these structural fibers do not need to be heating fibers.

[0179] In some aspects, the second portion 517 and the third portion 518 of layer 514 include the first portion 522 of fiber 520 (i.e., the heating fiber). In some aspects, the first portion 516 and the fourth portion 519 of layer 514 include the second portion 524 of fiber 520 (i.e., the structural fiber). In some aspects, the first portion 522 of fiber 520 is disposed between the second portions 524 of fiber 520.

[0180] In some respects, the top beam 500 includes multiple bands, including a first band 530 and a second band 532. Unless otherwise stated below, bands 530 and 532 may be used with... Figures 3A-3B The strips 322 and 324 are the same or similar. In some aspects, the first strip 530 is disposed in the top beam 500 adjacent to the first side 504. In some aspects, the second strip 532 is disposed in the top beam 500 adjacent to the second side 506. In some aspects, the strips 530 and 532 are embedded in the polymer 513 of the top beam 500 and are disposed at least partially between the second portion 517 and the third portion 518 of the layer 514 at the respective sides 504 and 506. The strips 530 and 532 may be coupled to the first portion 522 of the fiber 520 (i.e., the strips 530 and 532 are coupled to the heating fiber). In some aspects, the strips 530 and 532 are directly coupled to the heating fiber. In some aspects, when current is applied to the external circuit 540, the top beam 500 is configured to generate heat 550 between the first side 504 and the second side 506. Figure 5A (That is, heat is generated basically over the entire top beam).

[0181] The top beam according to various aspects of this disclosure can be configured to be heated over its substantially entire body by discrete heating elements. Reference Figures 6A-6B The present disclosure provides a top beam 600 for an upper body structure according to various aspects thereof, which, apart from the top beam 600, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 600 may be connected with... Figures 3A-3B The top beam 300 is the same. The top beam 600 includes an elongated body 602. The elongated body 602 extends between a first side 604 and a second side 606 (also referred to as "sides 604, 606"). The top beam 600 includes a first surface 608 and a second surface 610. In some aspects, such as Figure 6B As best shown, the IR reflector 612 is disposed adjacent to the first surface 608.

[0182] In some respects, the top beam 600 includes polymer 613 ( Figure 6B Polymer 613 may include an opaque polymer. Polymer 613 may be distributed throughout the body 602 of the top beam 600.

[0183] In some respects, the top beam 600 includes multiple layers 614 ( Figure 6B Layer 614 may include a first portion 616 and a second portion 617 of layer 614. In some aspects, all or a portion of layer 614 may be integrally formed. In some aspects, all or a portion of layer 614 may be integrally formed with the same polymer 613. The first portion 616 and the second portion 617 of layer 614 may include one of a plurality of fibers 620. Figure 6B In some respects, fiber 620 can be combined with... Figures 5A-5B The second part 524 of fiber 520 is the same as or similar to that of fiber 520 (i.e., fiber 620 may be a non-heated structural fiber).

[0184] In some aspects, the top beam 600 includes a heating element 622. The heating element 622 may be a discrete heating element. In some aspects, the heating element 622 is configured to be coupled to an external circuit 624 to generate heat 626 within the elongated body 602. Figure 6A In some respects, the heating element 622 includes a heating film.

[0185] In some respects, the top beam 600 includes multiple belts, including a first belt 630 and a second belt 632. Unless otherwise stated below, belts 630 and 632 may be used with... Figures 3A-3B The strips 322 and 324 are identical or similar. In some aspects, the first strip 630 is disposed in the top beam 600 adjacent to the first side 604. In some aspects, the second strip 632 is disposed in the top beam 600 adjacent to the second side 606. In some aspects, the conductive strips 630 and 632 are embedded in the top beam 600 and coupled to the heating element 622. In some aspects, the strips 630 and 632 are directly coupled to at least a portion of the heating element 622. In some aspects, when current is applied to the external circuit 624, the top beam 600 is configured to generate heat 626 between the first end 604 and the second end 606 (i.e., to generate heat substantially over the entire top beam).

[0186] In all respects, this disclosure provides at least a partially transparent top beam, as will be described below. Figure 7A-10CThe discussion is described in more detail. In all respects, a transparent roof beam improves occupant visibility compared to a substantially opaque roof beam. At least a portion (or optionally substantially the entire transparent roof beam) of the transparent roof beam may have a transparency or average light transmittance of greater than or equal to about 4% and less than or equal to about 99%, or optionally greater than or equal to about 50% and less than or equal to about 99%. In some respects, the portion may have a transparency of approximately 4%, optionally approximately 10%, optionally approximately 15%, optionally approximately 20%, optionally approximately 25%, optionally approximately 30%, optionally approximately 35%, optionally approximately 40%, optionally approximately 45%, optionally approximately 50%, optionally approximately 55%, optionally approximately 60%, optionally approximately 65%, optionally approximately 70%, optionally approximately 75%, optionally approximately 80%, optionally approximately 85%, optionally approximately 90%, or optionally approximately 95%. In some respects, the transparency is less than or equal to approximately 100%, optionally less than or equal to approximately 90%, optionally less than or equal to approximately 80%, optionally less than or equal to approximately 70%, optionally less than or equal to approximately 60%, optionally less than or equal to approximately 50%, optionally less than or equal to approximately 40%, optionally less than or equal to approximately 30%, optionally less than or equal to approximately 20%, or optionally less than or equal to approximately 10%.

[0187] In some respects, the top beam may include multiple regions with customized strength, thermal conductivity, and transparency. For example, regions expected to experience higher loads may have high strength (e.g., near the top beam and roof longitudinal beam joints and / or strut joints) and a higher fiber volume percentage. Regions expected to experience lower loads (e.g., near the centerline of the top beam) may include transparent polymers and have a reduced fiber volume percentage or be essentially fiberless. In some respects, regions with a higher fiber volume percentage and higher strength are generally less transparent than regions with a lower fiber volume percentage and lower strength, as will be discussed below. Figure 8A-10C It is described in more detail in the discussion.

[0188] The top beam according to various aspects of this disclosure can be configured to be heated by heating fibers over one or more regions or portions of its body, said one or more regions or portions being smaller than the entire body. In some aspects, at least a portion of the top beam is at least partially transparent. Reference Figures 7A-7C The present disclosure provides a top beam 700 for an upper body structure according to various aspects thereof, which, apart from the top beam 700, may be similar to... Figure 1The upper body structure 100. Unless otherwise stated below, the top beam 700 may be connected with... Figures 4A-4C The top beam 400 is identical. The top beam 700 includes an elongated body 702. The elongated body 702 extends between a first side 704 and a second side 706 (also referred to as "sides 704, 706"). The top beam 700 includes a first surface 708 and a second surface 710. In some aspects, such as Figure 7B As best shown in –7C, the IR reflector 712 is disposed adjacent to the first surface 708.

[0189] In some aspects, the top beam 700 may include one or more regions, such as a first outer region 724 and a second outer region 726 (also referred to as "outer regions 724, 726"). In some aspects, the top beam 700 may include an inner region 728 disposed between the first outer region 724 and the second outer region 726.

[0190] In some respects, the top beam 700 includes polymer 730 ( Figure 7B –7C). Polymer 730 may include a transparent polymer. In some aspects, the outer regions 724, 726 and the inner region 728 may be integrally formed using the same polymer 730. In some other aspects, polymer 730 may include more than one polymer, such as a first polymer in the outer regions 724, 726 and a second polymer in the inner region 728. The first polymer in the outer regions 724, 726 may be substantially opaque. The second polymer in the inner region 728 may be substantially transparent.

[0191] In some respects, external regions 724, 726 and Figures 4A-4B The outer regions 424 and 426 are the same or similar, unless otherwise stated below. Figure 7B As best shown, the first outer region 724 and the second outer region 726 ( Figure 7A Both can include with Figures 3A-3B Fiber 320 and Figures 4A-4C The first plurality of fibers 740 are identical or similar to fibers 420. In some aspects, the first fiber 740 may include a heating fiber, which may be a structural heating fiber, such as carbon fiber. In some aspects, the outer regions 724, 726 may be substantially opaque.

[0192] refer to Figure 7CThe internal region 728 includes a second plurality of fibers 750. In some aspects, the second fibers 750 may be heated fibers (e.g., structural heated fibers, such as carbon fibers). In some other aspects, the second fibers 750 may be structural fibers (e.g., basalt fibers, glass fibers, and / or aramid fibers). The second fibers 750 may form a plurality of bundles 752, which are locally (e.g., by means of tape) arranged in a geometry, such as a plurality of closed curves defining an open internal region. In some aspects, such as Figure 7D As best shown, the fiber bundle 752 can be formed into multiple substantially hexagonal shapes. However, these fibers can be arranged in different or additional patterns to define open areas, such as circles, triangles, squares, rhombuses, trapezoids, pentagons, heptagons, octagons, and other polygons. In some aspects, the placement of the second fiber 750 on the fiber bundle 752 can form multiple substantially fiber-free internal regions 754. In some aspects, the internal regions 754 can be substantially transparent. In some aspects, the internal regions 728 are at least partially transparent.

[0193] In some respects, the top beam 700 includes multiple bands, including a first band 760, a second band 762, a third band 764, and a fourth band 766. Unless otherwise stated below, bands 760, 762, 764, and 766 may be used with... Figures 4A-4C The bands 440, 442, 444, and 446 are the same or similar. When current is applied to the first external circuit 770, the first external region 724 can be configured to generate heat 771 between the first band 760 and the second band 762. Figure 7A Similarly, when current is applied to the second external circuit 772, the second external region 726 can be configured to generate heat 771 between the third band 764 and the fourth band 766.

[0194] In some respects, such as when the second fiber 750 includes heating fibers, the inner region 728 may be configured to generate heat locally along the filament bundle 752 (not shown). In other respects, such as when the second fiber 750 includes structural fibers, the inner region 728 may not have heating characteristics.

[0195] The top beam according to various aspects of this disclosure can be configured to be heated by heating fibers over one or more regions or portions of its body, said one or more regions or portions being smaller than the entire body. In some aspects, at least a portion of the top beam is transparent. Reference Figures 8A-8C The present disclosure provides a top beam 800 for an upper body structure according to various aspects thereof, which, apart from the top beam 800, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 800 may be connected with... Figures 7A-7CThe top beam 700 is the same. The top beam 800 includes an elongated body 802. The elongated body 802 extends between a first side 804 and a second side 806 (also referred to as "sides 804, 806"). The top beam 800 includes a first surface 808 and a second surface 810. In some aspects, such as Figure 8B As best shown in –8C, the IR reflector 812 is disposed adjacent to the first surface 808.

[0196] In some respects, the top beam 800 may include one or more regions, such as a first outer region 824 and a second outer region 826 (also referred to as "outer regions 824, 826"). The outer regions 824, 826 may be... Figures 7A-7B The outer regions 724 and 726 are the same as or similar to the outer regions 824 and 726. In some respects, the top beam 800 may include an inner region 828 at least partially disposed between the first outer region 824 and the second outer region 826. Unless otherwise stated below, the inner region may be similar to the outer region 824 and 726. Figures 7A-7C The internal regions 728 are the same or similar.

[0197] In some respects, the top beam 800 includes polymer 829 ( Figure 8B –8C). Polymer 829 may include a transparent polymer. In some aspects, the outer regions 824, 826 and the inner region 828 may be integrally formed using the same polymer 829. In some other aspects, polymer 829 may include more than one polymer, such as a first polymer in the outer regions 824, 826 and a second polymer in the inner region 828. The first polymer in the outer regions 824, 826 may be substantially opaque. The second polymer in the inner region 828 may be substantially transparent.

[0198] In some respects, such as Figure 8B As best shown, the first outer region 824 and the second outer region 826 ( Figure 8A Both include multiple fibers 830. Fibers 830 may include heating fibers, which may be structural heating fibers. In some aspects, the outer regions 824, 826 are substantially opaque. In some aspects, the outer regions 824, 826 may have a transparency greater than or equal to 0% to less than or equal to about 75%. In some aspects, such as Figure 8C As best shown, the inner region 828 is substantially fiber-free. In some respects, the inner region 828 is substantially transparent. In some respects, the inner region 828 has a transparency of greater than or equal to 0% to less than or equal to approximately 92%.

[0199] In some aspects, the top beam 800 includes multiple belts, including a first belt 860, a second belt 862, a third belt 864, and a fourth belt 866. Belts 860, 862, 864, and 866 can be coupled with... Figures 7A-7CThe bands 760, 762, 764, and 766 are the same or similar. In some respects, when current is applied to the first external circuit 870, the first external region 824 may be configured to generate heat 871 through the body 802 between the first band 860 and the second band 862. Figure 8A Similarly, when current is applied to the second external circuit 872, the second external region 826 can be configured to generate heat 871 between the third band 864 and the fourth band 866. In some respects, the internal region 828 has no heat-generating characteristics.

[0200] The top beam according to various aspects of this disclosure can be configured to be heated by discrete heating elements over one or more regions or portions of its body, said regions or portions being smaller than the entire body. In some aspects, at least a portion of the top beam is transparent. Reference Figures 9A-9C The present disclosure provides a top beam 900 for an upper body structure according to various aspects thereof, which, apart from the top beam 900, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 900 may be connected with... Figures 8A-8C The top beam 800 is the same. The top beam 900 includes an elongated body 902. The elongated body 902 extends between a first side 904 and a second side 906 (also referred to as "sides 904, 906"). The top beam 900 includes a first surface 908 and a second surface 910. In some aspects, such as Figure 9B As best shown in –9C, the IR reflector 912 is disposed adjacent to the first surface 908.

[0201] In some respects, the top beam 900 may include one or more regions, such as a first outer region 924 and a second outer region 926 (also referred to as "outer regions 924, 926"). Unless described below, outer regions 924, 926 may be related to Figures 8A-8B The outer regions 824 and 826 are the same or similar. In some respects, the top beam 900 includes an inner region 928 disposed between the first outer region 924 and the second outer region 926. The inner region 928 may be... Figures 8A-8C The internal regions 828 are the same or similar.

[0202] In some respects, the top beam 900 includes polymer 929 ( Figure 9B–9C). Polymer 929 may include a transparent polymer. In some aspects, the outer regions 924, 926 and the inner region 928 may be integrally formed using the same polymer 929. In some other aspects, polymer 929 may include more than one polymer, such as a first polymer in the outer regions 924, 926 and a second polymer in the inner region 928. The first polymer in the outer regions 924, 926 may be substantially opaque. The second polymer in the inner region 928 may be substantially transparent.

[0203] In some respects, such as Figure 9B As best shown, the first outer region 924 and the second outer region 926 ( Figure 9A Both include multiple fibers 930. Fiber 930 can be combined with... Figures 6A-6B Fiber 920 is the same as or similar to fiber 620. In some respects, fiber 930 includes structural fibers. In some respects, such as Figure 9C As best shown, the inner region 928 is fiber-free. In some respects, the inner region 928 is substantially transparent.

[0204] In some respects, each of the outer regions 924, 926 includes a heating element 932. Figure 9B The heating element 932 can be... Figures 6A-6B The heating element 932 is the same as or similar to a discrete heating element 622. In some aspects, the heating element 932 is a heating film. In some aspects, the heating element 932 is substantially transparent. In some other aspects, the heating element 932 is substantially opaque. In some aspects, the outer regions 924, 926 are at least partially transparent, for example when a low volume percentage of fibers 930 is present and the heating element 932 is substantially transparent. In some other aspects, the outer regions 924, 926 are substantially opaque, for example when a high volume percentage of fibers 930 is present and the heating element 932 is substantially opaque.

[0205] In some respects, the top beam 900 includes multiple bands, including a first band 960, a second band 962, a third band 964, and a fourth band 966. Unless otherwise stated below, bands 960, 962, 964, and 966 may be used with... Figures 7A-7C The bands 760, 762, 764, and 766 are the same or similar. In some respects, when current is applied to the first external circuit 970, the first external region 924 can be configured to generate heat 971 through the body 902 between the first band 960 and the second band 962. Figure 9A Similarly, when current is applied to the second external circuit 972, the second external region 926 can be configured to generate heat 971 between the third band 964 and the fourth band 966. In some respects, the internal region 928 has no heat-generating characteristics.

[0206] The top beam according to various aspects of this disclosure can be configured to be heated over one or more regions or portions of its body by both heating fibers and discrete heating elements, said one or more regions or portions being smaller than the entire body. In some aspects, at least a portion of the top beam is transparent. Reference Figures 10A-10C The present disclosure provides a top beam 1000 for an upper body structure according to various aspects thereof, which, apart from the top beam 1000, may be similar to... Figure 1 The upper body structure 100. Unless otherwise stated below, the top beam 1000 may be connected with... Figures 8A-8C The top beam 800 is the same. The top beam 1000 includes an elongated body 1002. The elongated body 1002 extends between a first side 1004 and a second side 1006 (also referred to as "sides 1004, 1006"). The top beam 1000 includes a first surface 1008 and a second surface 1010. In some aspects, such as Figure 10B As best shown in –10C, the IR reflector 1012 is disposed adjacent to the first surface 1008.

[0207] In some aspects, the top beam 1000 may include one or more regions, such as a first outer region 1024 and a second outer region 1026 (also referred to as "outer regions 1024, 1026"). In some aspects, the top beam 1000 includes an inner region 1028 disposed between the first outer region 1024 and the second outer region 1026.

[0208] In some respects, the top beam 1000 includes polymer 1029 ( Figure 10B –10C). Polymer 1029 may include a transparent polymer. In some aspects, outer regions 1024, 1026 and inner region 1028 may be integrally formed using the same polymer 1029. In some other aspects, polymer 1029 may include more than one polymer, such as a first polymer in outer regions 1024, 1026 and a second polymer in inner region 1028. The first polymer in outer regions 1024, 1026 may be substantially opaque. The second polymer in inner region 1028 may be substantially transparent.

[0209] In some respects, such as Figure 10B As best shown, the first outer region 1024 and the second outer region 1026 ( Figure 10A Both include multiple fibers 1030. Fiber 1030 can be combined with... Figures 8A-8B The fibers 830 are the same as or similar to those fibers. In some respects, the outer regions 1024, 1026 also include discrete heating elements 1032. The discrete heating elements 1032 may be compatible with... Figures 5A-5B Heating element 526 and Figures 9A-9BThe heating elements 932 are the same or similar, except that the discrete heating element 1032 is adjacent to the second surface 1010 of the top beam 1000.

[0210] In some respects, such as Figure 10C As best shown, the internal region 1028 is fiber-free. In some respects, the internal region 1028 has no discrete heating elements. In some respects, the internal region 1028 is substantially transparent and has no heating properties.

[0211] In some respects, the top beam 1000 includes multiple belts, including a first belt 1060, a second belt 1062, a third belt 1064, and a fourth belt 1066. Unless otherwise stated below, belts 1060, 1062, 1064, and 1066 may be used with... Figures 7A-7C The bands 760, 762, 764, and 766 are the same or similar. In some respects, when current is applied to the first external circuit 1070, the first external region 1024 can be configured to generate heat 1071 between the first band 1060 and the second band 1062. Figure 10A Similarly, when current is applied to the second external circuit 1072, the second external region 1026 can be configured to generate heat 1071 between the third band 1064 and the fourth band 1066.

[0212] In various aspects, this disclosure provides a method for manufacturing vehicle components such as roof beams. (Reference) Figure 13 The method typically includes forming a fiber mat comprising one or both of thermoplastic polymer fibers and structural fibers and / or heating fibers at 1300, forming a fiber mat assembly comprising the fiber mat and a backing at 1302, optionally removing one or more portions of the backing at 1304, forming a composite material at 1306, forming a vehicle component at 1308, and optionally coupling an additional component to the vehicle component at 1310. Each of these steps is described in more detail below.

[0213] Forming a fiber mat at 1300 may include blending a first plurality of fibers and a second plurality of fibers. The first plurality of fibers include thermoplastic polymer fibers. The second plurality of fibers include structural fibers and / or heating fibers (e.g., carbon fibers). In some aspects, the fiber mat may be referred to as a dry-blended fiber mat. The fiber mat may comprise one or more layers. The thermoplastic polymer fibers may include a first thermoplastic polymer. The structural and / or heating fibers may be arranged as needed based on the vehicle component to be formed. The first and second fibers may be uniformly or non-uniformly distributed within the fiber mat. For example, the structural and / or heating fibers may be arranged as described in any of the embodiments described above. In some aspects, the method may include forming more than one fiber mat.

[0214] In some aspects, the method may optionally include placing a portion of fibers (e.g., structural and / or heating fibers) into a plurality of filament bundles (e.g., via a belt). The filament bundles may be formed into geometric shapes, such as multiple polygons (e.g., hexagons). In some aspects, the method includes forming one or more fiber regions. In some aspects, two outer regions are formed, including a first fiber portion in a plurality of braided layers, and an inner region disposed between the two outer regions is formed, including a second fiber portion formed in the plurality of filament bundles.

[0215] Forming the fiber pad assembly at 1302 includes sewing the fiber pad to a backing, such as a polymer film. The polymer film may include a second thermoplastic polymer. The second thermoplastic polymer may be the same as or different from the first thermoplastic polymer. Embroidery techniques can be used to perform the sewing.

[0216] The fiber pad assembly may include additional components such as discrete heating elements, strips, and / or conductive paste. Therefore, forming the fiber pad assembly may also include adding discrete heating elements, such as heating films, to a plurality of fibers, for example, on one side of the fibers and / or embedded between fiber layers. Forming the fiber pad assembly may also include embedding conductive strips between the fibers and / or fiber layers. The method may further include applying conductive paste adjacent to the conductive strips.

[0217] The method may optionally include removing all or part of the backing at 1304. For example, a portion of the backing may be removed in a localized area where no structural or heating fibers are present. In some aspects, removal may include cutting. The resulting assembly may define a hole or other void space where the backing was removed.

[0218] Forming the composite material at 1306 includes consolidating a fiber pad assembly under heat and pressure. During consolidation, first and second thermoplastic polymers can melt and flow into the void space between structural and / or heated fibers that do not melt or flow during consolidation. Therefore, the composite material includes a polymer matrix and embedded structural and / or heated fibers. When the first and second thermoplastic polymers are identical, the resulting polymer matrix can have a single and substantially homogeneous structure, making the first and second polymers substantially indistinguishable and substantially without a boundary between them. The resulting composite material can be in sheet form or a desired three-dimensional shape. In some aspects, consolidation can include forming the composite material into a desired shape based on a vehicle part to be formed, for example, by using a heated mold. In some aspects, when the fibers include structural fibers, the composite material can be referred to as a structural composite material.

[0219] Forming a vehicle component at 1308 may include placing a composite material in a mold and injecting or injecting a polymer around at least a portion of the composite material. This polymer may include a third thermoplastic polymer. The third thermoplastic polymer may be the same as or different from the first thermoplastic polymer. The third thermoplastic polymer may be the same as or different from the second thermoplastic polymer. In one example, the first, second, and third thermoplastic polymers are all the same polymer (e.g., clear polycarbonate). In some aspects, the method may include placing the composite material into a mold and injection molding, injection compression molding, or injection molding to at least partially embed the composite material in the third thermoplastic polymer. The resulting vehicle component includes structural fibers and / or heating fibers embedded in a polymer matrix.

[0220] When the first, second, and third thermoplastic polymers are identical, the resulting polymer matrix of the vehicle component can have a single and substantially homogeneous structure, making the first, second, and third polymers substantially indistinguishable and leaving virtually no boundaries between them. In some other aspects, one or more of the first, second, and third thermoplastic polymers can be different. The first, second, and third thermoplastic polymers can be selected to have good matrix adhesion, such that the resulting polymer matrix is ​​substantially continuous. In some aspects, one or more of the first, second, and third thermoplastic polymers may include additives, such as pigments, to produce a colored polymer.

[0221] At 1310, the method optionally includes coupling the vehicle component to an additional component. In one example, the vehicle component is a roof beam, and the method further includes attaching an IR reflector, as described above.

[0222] Although the structures and related methods described herein are in the context of vehicle roof beams, they are also applicable to other vehicle components, such as doors, interior panels, structural components, etc. Furthermore, while this technology is particularly suitable for use in components of automobiles or other vehicles (e.g., motorcycles, boats, tractors, buses, motorcycles, trains, mobile homes, campervans, and tanks), it can also be used in a wide variety of other industries and applications, including, for example, aerospace components, consumer products, devices, buildings (e.g., houses, offices, sheds, warehouses), office equipment and furniture, as well as industrial equipment machinery, agricultural or agricultural equipment, or heavy machinery.

[0223] Example 1

[0224] refer to Figure 11A Thermal images of the heated portion of the top beam 1100 according to various aspects of this disclosure are provided. The top beam 1100 includes a plurality of carbon fibers 1102 ( Figure 11B (Also known as "carbon fiber 1102"). For example... Figure 11BAs best shown, carbon fiber 1102 is embroidered into woven fabric 1104. Top beam 1100 comprises multiple layers (not shown) of woven carbon fiber 1102. First and second copper strips are respectively placed on a first side or first end and a second side or second end (not shown) of top beam 1100. A current of 2 amperes (Amp) is applied to top beam 1100 via external circuitry 1108. Figure 11A A thermal image of the top beam 1100 is shown when a current of 2 amps is applied for 300 seconds.

[0225] Figure 11C Data set 1154 shows a graph of the relationship between the top beam temperature (℉) 1150 and time (seconds) 1152. As shown, when a current of 2 amperes is applied to the top beam 1100, the top beam temperature increases with time.

[0226] Figure 11C The dataset 1158 shows a graph of voltage (V) 1156 versus time (seconds) 1152. As shown, when a current of 2 amperes is applied to the top beam 1100, the voltage decreases as time increases.

[0227] Example 2

[0228] refer to Figure 12A The accompanying photographs provide top-view views of a partially transparent portion of the top beam 1200 according to various aspects of this disclosure. The top beam 1200 comprises a plurality of carbon fibers 1202. The carbon fibers 1202 form a plurality of filament bundles 1204, which are locally (e.g., by means of tape) arranged in a substantially hexagonal structure. Placing the carbon fibers 1202 within the filament bundles 1204 forms a plurality of substantially fiber-free internal regions 1206. The internal regions 1206 are substantially transparent.

[0229] Current is applied to the first end 1208 and the second end 1210 of this portion of the top beam 1200. An external circuit 1212 is formed by applying current to the top beam 1200. (Reference) Figure 12B It provides a thermal image of this part of the top beam 1200 when a current of 2 amps is applied for 300 seconds.

[0230] Figure 12C Data set 1254 shows a graph of the top beam temperature (℉) 1250 versus time (seconds) 1252 when a current of 2 amperes is applied. As shown, when a current of 2 amperes is applied to the top beam 1200, the top beam temperature increases with time.

[0231] Figure 12C Data set 1258 shows a graph of voltage (V) 1256 versus time (seconds) 1252. As shown, when a current of 2 amperes is applied to the top beam 1200, the voltage decreases as time increases.

[0232] A current of 1.6 amps is applied to the top beam 1200 via external circuit 1212. Figure 12D Dataset 1264 shows a graph of the top beam temperature (℉) 1260 versus time (seconds) when a current of 1.6 amperes is applied. As shown, when a current of 1.6 amperes is applied to the top beam 1200, the top beam temperature increases with time.

[0233] Figure 12D Data set 1268 shows a graph of voltage (V) 1266 versus time (seconds) 1262. As shown, when a current of 1.6 amperes is applied to the top beam 1200, the voltage decreases as time increases.

[0234] refer to Figure 12E This illustrates the heating portion of the top beam 1200 when current is applied through the external circuit 1212. Figure 12B A line scan of the thermal image 1269 is provided. A graph showing the relationship between temperature (℉) 1270 and thermal image pixels 1272 is also provided. As shown, the temperature is highest at the filament bundle 1204, which includes carbon fiber 1202. The temperature is relatively lowest in the internal region 1206, which is essentially free of carbon fiber 1202. The conductive carbon fiber 1202 in the top beam 1200 generates heat when current is applied through the external circuit 1212.

[0235] The foregoing description of embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or limiting of this disclosure. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and may be used in selected embodiments, even if not specifically shown or described. They may also vary in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A vehicle component, comprising: Polymer matrix; Multiple fibers in the polymer matrix; as well as A heating element embedded in the polymer matrix, the heating element being: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii), wherein the heating element is configured to be coupled to an external circuit to generate heat. The vehicle component is a roof beam, which includes an elongated body extending between a first side and a second side. The plurality of fibers comprises multiple portions, including a first portion and a second portion. The first portion comprises multiple layers of fibers, and the second portion comprises multiple bundles of fibers that cooperate to form a substantially polygonal shape. The top beam is configured to be heated by heating elements on one or more portions of its main body, the one or more portions being smaller than the entire main body.

2. The vehicle component according to claim 1, wherein: The heating element includes at least a portion of the plurality of fibers, and At least a portion of the plurality of fibers includes carbon fibers.

3. The vehicle component according to claim 1, wherein, The heating element includes a discrete heating element, the discrete heating element includes a membrane, and the membrane includes at least one layer.

4. The vehicle component according to claim 3, wherein, The discrete heating element comprises a material selected from the group consisting of indium tin oxide (ITO), graphene, carbon nanotubes (CNTs), silver nanowires, or combinations thereof.

5. The vehicle component according to claim 1, wherein, The plurality of fibers are selected from the group consisting of: carbon fiber, glass fiber, basalt fiber, aramid fiber, natural fiber, polyethylene fiber, polypropylene fiber, or any combination thereof.

6. The vehicle component according to claim 1, wherein, The plurality of fibers include multilayer woven fibers.

7. The vehicle component according to claim 1, wherein: The plurality of filament bundles include (i) heating fibers such that the second portion is configured to locally generate heat along the filament bundle; or (ii) structural fibers such that the second portion has no heating characteristics.

8. The vehicle component according to claim 1, wherein, The elongated body also includes an infrared (IR) reflector disposed adjacent to a first surface of the elongated body.

9. The vehicle component according to claim 1, wherein, The elongated body also includes a plurality of conductive strips configured to electrically couple the heating element to the external circuit, the plurality of conductive strips including copper strips.

10. The vehicle component according to claim 9, wherein: The plurality of conductive strips includes a first conductive strip and a second conductive strip. The first conductive strip is coupled to the first side, and the second conductive strip is coupled to the second side. The elongated body is configured to generate heat between the first side and the second side.

11. The vehicle component according to claim 9, wherein: The heating element includes a first heating element and a second heating element. The plurality of conductive strips includes a first conductive strip, a second conductive strip, a third conductive strip, and a fourth conductive strip, and The elongated body also includes: A first region includes a first heating element extending between a first end and a second end, a first conductive strip coupled to the first end, and a second conductive strip coupled to the second end, the first region being configured to generate heat between the first end and the second end. A second region comprising a second heating element extending between a third end and a fourth end, the third conductive strip being coupled to the third end and the fourth conductive strip being coupled to the fourth end, the second region being configured to generate heat between the third end and the fourth end. A third region is located between the first region and the second region, and the third region does not have the heating element.

12. A vehicle roof beam, comprising: An elongated body extending between a first side and a second side, the elongated body comprising: polymer matrix, The polymer matrix contains multiple fibers, and A heating element embedded in the polymer matrix, the heating element being: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii), wherein, At least a first portion of the elongated body is configured to be coupled to an external circuit to generate heat within the elongated body, and At least the second portion of the elongated body has a transparency greater than or equal to approximately 0%. The plurality of fibers comprises multiple portions, including a first portion and a second portion. The first portion comprises multiple layers of fibers, and the second portion comprises multiple bundles of fibers that cooperate to form a substantially polygonal shape. The vehicle roof beam is configured to be heated by heating elements on one or more portions of its main body, the one or more portions being smaller than the entire main body.

13. The vehicle roof beam according to claim 12, wherein, The elongated body also includes a plurality of conductive strips configured to electrically couple the heating element to the external circuit.

14. The vehicle roof beam according to claim 13, wherein: The heating element includes a first heating element and a second heating element. The plurality of conductive strips includes a first conductive strip, a second conductive strip, a third conductive strip, and a fourth conductive strip, and The elongated body includes: A first region includes a first heating element extending between a first end and a second end, a first conductive strip coupled to the first end, and a second conductive strip coupled to the second end, the first region being configured to generate heat between the first end and the second end. A second region comprising a second heating element extending between a third end and a fourth end, the third conductive strip being coupled to the third end and the fourth conductive strip being coupled to the fourth end, the second region being configured to generate heat between the third end and the fourth end. A third region is located between the first region and the second region, wherein the third region does not have the heating element.

15. The vehicle roof beam according to claim 14, wherein, The first and second regions have a transparency of about 0% to about 75%, and the third region has a transparency of about 0% to about 92%.

16. The vehicle roof beam according to claim 12, wherein, The heating element includes a discrete heating element, the discrete heating element including a membrane, the membrane being: (i) at least partially transparent; (ii) at least partially opaque; or both (i) and (ii).

17. A method for manufacturing a vehicle component, the method comprising: Prepare a fiber mat comprising a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers comprise a first thermoplastic polymer, and the second plurality of fibers comprise structural fibers, heating fibers, or both structural fibers and heating fibers; A fiber pad assembly is formed by stitching the fiber pad to a backing, the backing comprising a membrane comprising a second thermoplastic polymer; The composite material is formed by consolidating the fiber pad assembly under heat and pressure. as well as The vehicle component is formed by injecting a third thermoplastic polymer around at least a portion of the composite material. The method further includes forming two outer regions comprising first fiber portions in a plurality of braided layers, and forming an inner region disposed between the two outer regions comprising second fiber portions formed in a plurality of filament bundles, the plurality of filament bundles cooperating to form a substantially polygonal shape. The vehicle components include: Polymer matrix; The plurality of fibers in the polymer matrix; and A heating element embedded in the polymer matrix, the heating element being: (i) a discrete heating element; (ii) at least a portion of the plurality of fibers; or both (i) and (ii), wherein the heating element is configured to be coupled to an external circuit to generate heat. The vehicle component is a roof beam, which includes an elongated body extending between a first side and a second side, and wherein the roof beam is configured to be heated by heating elements on one or more portions of its body, the one or more portions being smaller than the entire body.

18. The method according to claim 17, wherein, The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer comprise polycarbonate, and The second plurality of fibers includes carbon fibers.

Images