Roof covering with contact elements

Abstract

The invention relates to a cover (3) of a roof (1), having a pane (6), an electrical device (12) arranged on the pane (6), and a contact unit (13) arranged on the pane (6), connected to the electrical device (12) and having at least one contact point (16) for contact with a connector. According to the invention, the contact unit (13) is arranged on a pane underside (14) of the pane (6), and a contact housing (15) of the contact unit (13) is foam-encapsulated by a cover foam (25) with the at least one contact point (16) remaining exposed.

Description

Technical Field

[0001] The present invention relates to a roof cover having a window pane, an electrical device arranged on the window pane, and a contact unit arranged on the window pane, connected to the electrical device, and having at least one contact point for contacting a connector. Background Technology

[0002] A glass panel for a vehicle is known from EP 0 619 691 B2, which includes, for example, an electrical device having an electrically heated resistance wire. The electrical connection or power supply from the vehicle side is provided via a connecting cable inserted into a plug disposed at and extending laterally from the side edge of the glass panel, and encased by means of a foam covering portion mounted at the side edge of the glass panel. Summary of the Invention

[0003] The objective of this invention is to realize a cover as described at the beginning, wherein the cover has improved electrical connections, and to provide a method for manufacturing such a cover.

[0004] The task is accomplished in the cover described at the beginning by means of the following method according to the invention: the contact unit is arranged on the lower side of the window pane, and the contact housing of the contact unit is encapsulated by the foam portion of the cover while keeping the at least one contact point exposed.

[0005] Furthermore, the task is solved by the method according to claim 9.

[0006] Advantageous configurations of the invention are given in the dependent claims.

[0007] By arranging the contact unit on the underside of the window pane, the side edges of the window pane and cover are not affected by the plug extending laterally at the side edges, the arrangement of which is known from EP 0 619 691 B2 as described at the beginning. Therefore, a cover fixedly arranged in a roof opening or movably arranged as part of a sliding sunroof can be securely sealed at its side edges by means of a seal. The cover foam provides a durable and protected installation of the contact unit by foam encapsulation or foam covering (e.g., by means of polyurethane foam in a foaming tool). Here, at least one contact arranged in the contact housing is not covered by the cover foam or has no such cover foam, making the contact freely accessible for contact with a contact plug such as a cable. The cover foam is particularly configured such that its foam encapsulation or foam covering covers a frame or reinforcing frame or reinforcing member, and securely holds them on the underside of the cover or window pane. Such a reinforced cover frame is arranged, for example, along at least one side edge of the cover, inwardly and adjacent to that side edge, and particularly around the cover, and may also have a fixing portion for a support device for supporting the cover. Preferably, the cover foam forms a window pane or a lateral edge foam encapsulation of the cover, and may also include or form a lateral light shield. Contact units are thus arranged in accordance with their purpose in the cover foam surrounding the side edges of the cover, particularly on the edge sides. Preferably, such contact units are arranged at each of two side edges of the cover that extend in the longitudinal direction of the cover and are opposite to each other.

[0008] "Glass pane" refers not only to a pane with only one panel, but also to a pane with multiple panels or panes, such as a composite glass pane with two or more panes or panels.

[0009] Depending on the destination, at least one contact of the contact unit is configured as a contact socket, but it can also be configured as a contact plug. Therefore, a plug component to be inserted into the contact unit has either a contact plug or a contact socket. However, the contact unit can also have contacts configured in other ways.

[0010] Preferably, the connecting wires that connect the electrical device to the contact unit are foam-covered within the foamed portion of the cover. The connecting wires are fully covered with foam, except for the electrical device, or at least in the section extending from the contact unit. The connecting wires are thus permanently protected. By foam-covering the contact unit and connecting wires together, there is no need for a dedicated seal for the connecting wires in the foaming tool, such as at the transition point from the foamed portion of the cover.

[0011] As intended, the contact unit is secured to the underside of the window pane by means of an adhesive component. This adhesive component is configured to position and hold the contact unit firmly to the underside of the window pane when the cover foam is foamed onto the window pane in a foaming tool. Therefore, the connecting lines securely connected to the contact unit are also properly positioned by the contact unit fixed to the underside of the window pane.

[0012] According to a preferred embodiment, the contact housing has a contact area including at least one contact point and a sealing area surrounding the contact area on its side opposite to the lower side of the window pane. The sealing area is configured to couple a sealing element. The sealing element is arranged in a sealed position in the sealing area when the cover foam portion is foamed and molded, and seals the contact area relative to the cover foam portion to be foamed and molded. Thus, the sealing element is a manufacturing aid that keeps the contact area exposed relative to the foam material in the foaming tool, and also protects the contact area of ​​the cover ready to be installed on the roof after the cover foam portion has been foamed and molded until the cover is installed on the roof.

[0013] The sealing element is made of, for example, rubber or elastic plastic.

[0014] According to the destination configuration, the contact housing has a bracket or is configured to detachably mount the sealing element. Such a bracket can hold the sealing element to the contact housing before the pane is inserted into the foaming tool and until the foaming tool is closed. In principle, the bracket can be designed such that it holds the sealing element in place by means of form-locking and friction-locking. Alternatively, the sealing element can also be positioned or held in the open foaming tool, for example, on a tool insert, and rest against the contact housing when the foaming tool is closed.

[0015] In a preferred embodiment, the electrical device has a functional layer or electrical thin film, such as a light-emitting film, arranged on the pane or between the first and second panes of a composite glass panel formed by two panes in the cover. The pane or composite glass panel thus has, for example, an inner pane and an outer pane, between which the electrical thin film or light-emitting film is laminated by means of a laminating layer. The functional layer or electrical thin film is, for example, a switchable PDLC (polymer-dispersed liquid crystal) film, through which the light transmission through the pane can be controlled.

[0016] Another preferred embodiment is provided, alternative to or additional to the functional layer, that the electrical device has at least one optical coupling element, which is preferably arranged from the contact unit toward the lower side of the window pane and configured to allow light to enter the window pane.

[0017] Depending on the configuration and arrangement of the electrical device, the connection lines between the electrical device and the contact unit can be arranged such that they surround the edge of the window pane and are encased in foam within the cover foam section. Thus, the connection lines are fixed and protected as a whole by the cover foam section.

[0018] The cover is, for example, a movable roof element of a vehicle roof or a non-openable fixed roof element such as an FTM (Fixed Type Module). The cover is particularly part of an openable roof system (e.g., a spoiler roof or sliding sunroof) and is arranged in a roof opening in its closed position. The cover is, for example, a transparent cover or a glass cover. The cover is movably supported on the roof by means of a support device and can be displaced above or below an adjacent roof surface portion during longitudinal opening movement.

[0019] A method for manufacturing a roof cover according to the invention, the roof cover having a window pane, an electrical device arranged on the window pane, and a contact unit connected to the electrical device and having at least one contact point for contacting a connector, particularly a roof cover according to any one of claims 1 to 8, characterized by the following steps: a) Inserting the pane into the first mold half of the opened foaming tool, wherein the pane faces the second mold half of the foaming tool with its lower pane side pointing towards it, and having a contact unit fixed thereon on its lower pane side. (b) Provide a sealing element configured to fit tightly against a sealing region of the contact housing of the contact unit, the sealing region being formed on the contact side of the contact unit away from the lower side of the window pane and surrounding the contact region of the contact housing, wherein the sealing element is held on the sealing region of the contact housing or on the second mold half, particularly on the tool insert of the second mold half. c) Closing the foaming tool, wherein the sealing element is positioned in a position relative to the cavity sealing contact area of ​​the foaming tool. d) Introducing plastic foam material into the cavity and foaming the cover portion, wherein the contact area with the shell is kept exposed by the cover foam portion, and e) Open the foaming tool to remove the cap from the foaming tool.

[0020] The sealing element can be removed from the cover to expose the contact area of ​​the contact housing, while the cover remains in the open foaming tool. Alternatively, the sealing element can remain on the cover and protect the contact area until the cover is installed on the roof and the plug is inserted into the contact housing or contacts. In either case, the sealing element is reusable when manufacturing a replacement cover.

[0021] The cover according to the invention and its manufacture have several advantages. By sealing the contact housing relative to the cavity and foam-covering the connecting lines at the contact housing, the necessity for a non-foamed area is eliminated, which would otherwise surround the contact housing and the contact area in cases where a separate seal for the connecting lines on the contact housing using foaming tools is required. The cover according to the invention reduces the installation space required for foam-covering the contact housing.

[0022] The sealing element is inserted into the contact housing without requiring high positioning accuracy of the contact housing in the panes arranged in the foaming tool, which would be necessary if the sealing element were fixedly positioned in the foaming tool and oriented toward the contact housing.

[0023] The contacts of the contact unit are protected from foam material intrusion by a sealing element that is inserted into the contact housing and compressed in the foaming tool for sealing, and a blank area is created in the contact area for the plug to be inserted. Damage to the connection lines is eliminated by applying pressure to the contact housing, rather than to the connection lines. Attached Figure Description

[0024] The invention will be explained in more detail below with reference to the accompanying drawings and by means of an embodiment of the cover according to the invention. The drawings show: Figure 1 The perspective view shows a roof with a cover arranged in an opening in the roof. Figure 2 The side edge region of the cover with contact units having foam covering the foamed portion of the cover is shown in the cross-sectional view. Figure 3 The lateral region of the cover is shown in an isometric bottom view, which has a cover foam section containing contact units; Figure 4 According to Figure 2 The cross-sectional view shows the side edge region of a cover arranged on one half of a foaming tool, which has a contact unit and a sealing element arranged on the contact unit. Figure 5 The contact unit with connecting lines is shown in the isometric view; Figure 6 A tool half with an adjustable tool insert is shown in an isometric view, the tool insert being configured to press against a sealing element arranged on a contact unit. Figure 7 According to Figure 6 The isometric view shows a diagram of the tool half with contact units and a sealing element abutting against the tool insert; Figure 8A partial view of the lateral cover edge region of a sealing element with a foam-covered contact unit is shown in an isometric view. Figure 9 According to Figure 2 The cross-sectional view shows the foam-covered contact unit and the sealing element covering the contact unit; and Figure 10 According to Figure 8 The isometric view shows the edge area of ​​the cover with foam-covered contact unit with the sealing element removed. Detailed Implementation

[0025] The roof 1 of a vehicle (such as a passenger car) has a roof opening 2 and a cover 3 that closes the roof opening 2. The cover 3 is movably supported on the roof 1, allowing it to be selectively closed or at least partially exposed of the roof opening 2. The cover 3 is substantially movably supported on the roof 1, for example on the roof frame of the roof 1, allowing it to be moved rearward from its closed position along the longitudinal direction of the vehicle to above or below the rear roof surface 4. Thus, the cover 3 may be part of an openable roof system (e.g., a sliding sunroof, an externally guided sunroof, or a spoiler roof). The rear roof surface 4 may also be formed by or have a second cover 5, which is adjacent to the front cover 3 on the rear side. In an alternative configuration, the cover 3 may be fixedly mounted on the roof 1 for closing the roof opening 2.

[0026] Cover 3 has window pane 6 ( Figure 2 The pane 6 preferably comprises an inner pane 7 and an outer pane 8, between which a functional layer 9, such as a PDLC film (polymer dispersed liquid crystal), is laminated by means of two laminated layers 10 and 11. The pane 6 is thus constructed as a composite glass panel. The functional layer 9 constitutes at least a portion of an electrical device 12 arranged on the pane 6. This electrical device 12 may have other electrical or electronic components such as solar cells, lighting devices, or sensors. The inner pane 7 and outer pane 8 of the pane 6 are preferably transparent panes or glass panels.

[0027] Contact unit 13 is arranged on the inner side of the window pane 6, or the lower side 14 of the window pane. In this embodiment of the cover 3, the lower side of the inner window pane 7 constitutes the lower side 14 of the window pane 6 in the mounting position of the cover 3 on the roof 1. Contact unit 13 has a contact housing 15 having at least one contact 16 disposed therein, and preferably multiple contacts 16. The contact housing 15 is connected to the lower side 14 of the window pane 6 by means of an adhesive portion 18 (e.g., double-sided tape) on the base surface 17 of the contact housing 15 and is positioned such that the contacts 16 are arranged on the side opposite to the base surface 17 of the contact housing 15. Thus, the contacts 16 are accessible from below the window pane 6. The contact housing 15 is positioned inwardly toward the lower side of the cover 3, spaced apart from the side edge 19 of the cover 3, and still positioned in the edge region of the cover 3, the side edge 19 extending along one of the two longitudinal sides 20 of the cover 3.

[0028] The connecting line 21 is electrically connected to the contact 16 within the contact housing 15. The connecting line 21, preferably a flat ribbon cable, extends laterally from the contact housing 15 toward the window edge 22 of the inner window pane 7, surrounds the window edge 22, and rests at its end section 23 against the inner laminated side 24 of the inner window pane 7, which is laminated with the laminated layer 10. The connecting line 21 is electrically connected to the functional layer 9 at its end section 23. The end section 23 of the connecting line 21 is securely held in place on the inner window pane 7 by the window pane 6, which is laminated with the outer window pane 8.

[0029] The cover 3 has a cover foam portion 25, which is preferably formed circumferentially on the cover 3 or at least at the side edges 19 of each longitudinal side 20 of the cover 3. The cover foam portion 25 (e.g., a polyurethane foam portion) is designed to form lateral light shields 26 at each longitudinal side 20. From the side edge 19 or the light shield 26 toward the inside of the cover, a reinforcing member or cover frame (not shown) is foam-encapsulated in the cover foam portion 25, and for example, a cover support device (not shown) is fixed to the reinforcing member or cover frame. Contact units 13, which are foam-encapsulated by the cover foam portion 25, are arranged further inward in the transverse direction of the cover.

[0030] The contact housing 15 has a contact area 28 including a contact point 16 and a sealing area 29 on its side opposite to the lower side 14 of the window pane. Figure 4 The sealing region 29 surrounds the contact region 28 and is configured to tightly abut or couple the sealing element 30. The sealing element 30 is arranged in a sealed position on the sealing region 29 when the cover foam portion 25 is foamed in the foaming tool 31. Figure 4 In this sealed position, the sealing element abuts against the sealing area 29 with the abutment surface 32 and the cavity 34 of the foaming tool 31 is defined by the circumferential surface 33, and the cover foaming part 25 is foamed and molded onto the window 6 in the cavity.

[0031] The contact housing 15 has, for example, five contacts 16 (see...) Figure 5 These contacts are arranged in a row in a central contact area 28, which protrudes relative to the surrounding sealing area 29 and has surrounding sidewalls 35 against which the insert sealing element 30 is tightly abutted. The sealing element 30 has a central rectangular opening 36 that matches the contact area 28, sized such that the insert sealing element 30 is slightly opened by the contact area 28 under elastic deformation and thus held against the sidewalls 35 of the contact area 28 by frictional locking. Therefore, the protruding contact area 28 forms a support for the sealing element 30.

[0032] The foaming tool 31 has a punch-shaped tool insert 37, which is arranged in a recess 38 of the foaming tool 31 corresponding to the contact unit 13 and has an end-side support surface facing the contact unit 13 and configured to abut against the back side surface 39 of the sealing element 30. The tool insert 37 is arranged in an adjustable or height-adjustable manner in the direction toward the contact unit 13. Thus, the tool insert 37 can be matched with the corresponding sealing element 30 to be used, such that when the foaming tool 31 is closed and the foaming part 25 of the foamed cap is foamed, the sealing element 30 is pressed against the sealing area 29 of the contact housing 15. Here, a pressing force is provided such that the sealing element 30 maintains its position relative to the foaming material under foaming pressure in the cavity 34.

[0033] To manufacture the cover 3, a pane 6, which is a composite glass panel, is first provided. This pane includes an inner pane 7, an outer pane 8, two laminated layers 10 and 11, and a light-emitting film 9 sandwiched between them. Here, the end section 23 of the contact functional layer 9 of the connecting line 21 is laminated between the inner pane 7 and the outer pane 8. The connecting line 21 is arranged around the pane edge 22 of the inner pane 7 and extends inward on the lower side 14 of the pane to the contact housing 15 of the contact unit 13, in which the connecting line is electrically connected to the contact 16. The contact housing 15 is fixed to the lower side 14 of the pane by means of an adhesive portion 18 (e.g., tape). A sealing element 30 is inserted into the contact housing 15 such that the sealing element fits tightly against the sealing area 29 and is held by the contact area 28 that forms a support, which is embedded in the opening 36 of the sealing element 30.

[0034] The pane 6 is inserted into the first tool half or mold half (not shown) of the open foaming tool 31, wherein the upper side or outer side 40 of the pane 6 abuts against the first mold half, and the lower side 14 of the pane 6 abuts against the cavity 34 formed in the second tool half or mold half 41 when the foaming tool 31 is closed. The second mold half 41 is intended to include at least one reinforcing member, such as an insert or frame member (not shown), which is held by another tool insert (not shown) supported in the second mold half 41 and is to be foam-molded or foam-encapsulated in the cover foam portion 25. After the foaming tool 31 is closed, the tool insert 37 loads the sealing element 30, thereby maintaining its position when it is foam-molded with plastic foam material. The contact area 28 of the contact housing 15 is thus kept exposed from the plastic foam material of the cover foam portion 25. After the foaming tool 31 is opened, the cover 3 is removed from the foaming tool 31. The sealing element 30 is still arranged on the contact housing 15. Figure 8 and 9 The cover 3 is removed and can be used when another cover 3 is manufactured in the foaming tool 31. This exposes the contact area 28. Figure 10 ) and ready for insertion of plug 42 ( Figure 2 ). Plug 42 is connected to a cable such as a trailing cable for vehicle networking or to another electrical device in cover 3.

[0035] List of reference numerals 1. Roof 2. Roof opening 3. Cover 4. Roof surface 5. Cover 6 window panes 7. Interior window panes 8. Exterior window panes 9. Functional Layer 10-layer laminate 11 laminated layers 12 Electrical installations 13 Contact Units 14. Bottom of the window pane 15 Contact housing 16 contacts 17. Fundamentals 18 Adhesive Part 19 Side edges 20 Longitudinal side 21 Connection Line 22. Window pane edges 23 End Section 24 laminated side 25. Foaming section of the cover 26 visor 28 Contact Area 29 Sealed Area 30 Sealing elements 31 Foaming tools 32. Surface against 33 Circumferential Plane 34 cavities 35 Sidewall 36 Opening 37 Tool Embedded Components 38 recess 39. Dorsal and Lateral Sides 40 Outer side 41 Second mold half 42 plug

Claims

1. A roof cover (3) for a vehicle roof (1), the cover having a window pane (6), an electrical device (12) disposed on the window pane (6), and a contact unit (13) disposed on the window pane (6), connected to the electrical device (12), and having at least one contact point (16) for contacting a connector. Its features are, The contact unit (13) is arranged on the lower side (14) of the window pane (6), and the contact housing (15) of the contact unit (13) is foam-encapsulated by the cover foam portion (25) while keeping the at least one contact point (16) exposed.

2. The cover (3) according to claim 1. Its features are, The connecting line (21) that connects the electrical device (12) to the contact unit (13) is covered with foam in the foamed part (25) of the cover.

3. The cover (3) according to claim 1 or 2. Its features are, The contact unit (13) is connected to the lower side (14) of the window pane by means of an adhesive part (18).

4. The cover (3) according to any one of claims 1 to 3. Its features are, The contact housing (15) has a contact area (28) and a sealing area (29) on its side opposite to the lower side (14) of the window pane, the contact area including the contact point (16). The sealing region (29) surrounds the contact region (28) and is configured to couple a sealing element (30) which is arranged in a sealed position on the sealing region (29) during the foaming of the cover foam (25) and seals the contact region (28) relative to the cover foam (25) to be foamed.

5. The cover (3) according to claim 4. Its features are, The contact housing (15) has a bracket for detachably mounting the sealing element (30).

6. The cover (3) according to any one of claims 1 to 5. Its features are, The electrical device (12) has a functional layer (9) or an electrical film arranged on the window pane (6) or between the window pane and the second window pane of the composite glass plate formed by the two window panes of the cover (3).

7. The cover (3) according to any one of claims 1 to 6. Its features are, The electrical device (12) has at least one optical coupling element arranged from the contact unit (13) inward on the lower side (14) of the window pane (6) and configured to allow light to enter the window pane (6).

8. The cover (3) according to any one of claims 1 to 7. Its features are, The connection line (21) between the electrical device (12) and the contact unit (13) surrounds the window edge (22) of the window pane (6) and is covered with foam in the edge area of ​​the cover foam (25).

9. A method for manufacturing a cover (3) for a vehicle roof (1), the cover having a window pane (6), an electrical device (12) disposed on the window pane (6), and a contact unit (13) connected to the electrical device (12) and having at least one contact (16) for contacting a connector. Its features are, It includes the following steps: a) Insert the pane (6) into the first mold half of the open foaming tool (31), wherein the pane (6) points toward the second mold half of the foaming tool (31) with its lower pane side (14) facing it, and has a contact unit (13) fixed thereon on its lower pane side (14). b) Provide a sealing element (30) configured to fit tightly against a sealing region (29) of the contact housing (15) of the contact unit (13), the sealing region being formed on the contact side of the contact unit (13) away from the lower side (14) of the window pane and surrounding the contact region (28) of the contact housing (15), wherein the sealing element (30) is held on the sealing region (29) of the contact housing (15) or on the second mold half, particularly on the tool insert (37) of the second mold half. c) Close the foaming tool (31), wherein the sealing element (30) is positioned to seal the contact area (28) relative to the cavity (34) of the foaming tool (31). d) Introducing plastic foam material into the cavity (34) and foaming the cover foam portion (25), wherein the contact area (28) of the contact shell (15) is kept exposed by the cover foam portion (25), and e) Open the foaming tool (31) to remove the cover (3) from the foaming tool (31).

10. The method according to claim 9, Its features are, The sealing element (30) is removed to expose the contact area (28) of the contact housing (15), and is especially used for manufacturing additional covers (3).

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