A roof assembly and vehicle

Abstract

The application provides a roof assembly and a vehicle, and relates to the field of vehicles.The roof assembly comprises an interior layer, a transition layer, an energy absorption layer, a base layer and a protective layer which are sequentially stacked, and can meet the basic functions required by the roof assembly of the vehicle, such as protection, heat and sound insulation, buffering and energy absorption.In addition, the five structure layers are formed into an integrated structure through a molding process, that is, the roof assembly is an integrated structure, and subsequent assembly is not required, so that the number of parts and the assembly process are greatly reduced, and the weight of the roof assembly is effectively reduced based on the reduction of the assembly parts and the high integration of the structure of the roof assembly.

Description

Technical Field

[0001] This application relates to the field of vehicles, and in particular to a roof assembly and a vehicle. Background Technology

[0002] Traditional vehicle roof assemblies are typically assembled from multiple parts, such as outer panels, reinforcing beams, sound insulation pads, and inner lining panels, through welding, bonding, or other mechanical connections. This type of split roof assembly has a large number of parts, a large overall weight, and a complex and cumbersome assembly process. Summary of the Invention

[0003] In view of this, the purpose of this application is to provide a roof assembly and vehicle to solve the problems of the large number of parts, heavy weight and complicated assembly process of the existing split roof assembly.

[0004] In accordance with the above objectives, a first aspect of the present invention provides a top cover assembly, wherein the top cover assembly includes an interior layer, a transition layer, an energy-absorbing layer, a substrate layer, and a protective layer stacked sequentially; the interior layer, the transition layer, the energy-absorbing layer, the substrate layer, and the protective layer are formed into an integral structure by a molding process; and the substrate layer has a first connecting portion.

[0005] Preferably, the interior trim layer is formed as a knitted layer, a leather layer, or a linen fiber layer; the thickness of the interior trim layer is 0.8mm to 1.2mm.

[0006] Preferably, the transition layer is formed as a composite structural layer composed of fiberglass mat and structural adhesive, wherein the structural adhesive fills the pores of the fiberglass mat and the fiber surface; the thickness of the transition layer is 0.3 mm to 0.5 mm.

[0007] Preferably, the energy-absorbing layer is formed as a polyurethane foam layer or a polyester honeycomb composite core layer; the thickness of the energy-absorbing layer is 10mm~20mm; and the density of the energy-absorbing layer is 45 kg / m³~70kg / m³.

[0008] Preferably, the matrix layer is formed as a continuous long glass fiber reinforced thermoplastic composite material layer, and the thickness of the matrix layer is 2mm~3mm.

[0009] Preferably, the substrate layer has reinforcing ribs inside; the first connecting portion is formed at the end face of the substrate layer.

[0010] Preferably, the first connecting portion is formed as a countersunk hole structure, the inner sidewall of the countersunk hole is formed with internal threads, and the opening of the countersunk hole is located at the end face of the substrate layer.

[0011] Preferably, the protective layer is formed as an alkali-free glass fiber layer or a basalt fiber reinforced modified polypropylene prepreg layer, and the thickness of the protective layer is 1.2 mm to 1.8 mm.

[0012] According to a second aspect of the invention, a vehicle is provided, wherein the vehicle includes a roof assembly as described above.

[0013] Preferably, the vehicle body has a second connecting portion corresponding to the first connecting portion.

[0014] According to the roof assembly and vehicle of the present invention, the roof assembly includes an interior layer, a transition layer, an energy-absorbing layer, a base layer and a protective layer stacked sequentially, which can meet the basic functions required by the roof assembly of the vehicle, such as protection, heat insulation and sound insulation, and buffering and energy absorption. In addition, the above five structural layers are formed into an integral structure by molding process, that is, the roof assembly is an integral structure, which does not require subsequent assembly, greatly reducing the number of parts and assembly processes. Based on the reduction of assembly parts and the high integration of the structure of the roof assembly, the weight of the roof assembly is effectively reduced.

[0015] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of a top cover assembly according to an embodiment of the present invention; Figure 2 This is a schematic cross-sectional view of the top cover assembly at point AA according to an embodiment of the present invention; Figure 3 This is a cross-sectional view of the roof assembly and the vehicle body according to an embodiment of the present invention.

[0018] Icons: 1-Top cover assembly; 11-Interior layer; 12-Transition layer; 13-Energy absorption layer; 14-Base layer; 141-First connecting part; 15-Protective layer; 2-Vehicle body; 21-Second connecting part. Detailed Implementation The following detailed embodiments are provided to help the reader gain a comprehensive understanding of the methods, apparatus, and / or systems described herein. However, various changes, modifications, and equivalents of the methods, apparatus, and / or systems described herein will be apparent after understanding the disclosure of this application. For example, the order of operations described herein is merely illustrative and is not limited to the order set forth herein; changes that will be apparent after understanding the disclosure of this application are possible, except for operations that must occur in a specific order. Furthermore, for clarity and brevity, descriptions of features known in the art may be omitted.

[0019] The features described herein may be implemented in different forms and should not be construed as being limited to the examples described herein. Rather, the examples described herein have been provided merely to illustrate some of the many feasible ways of implementing the methods, apparatus, and / or systems described herein that will be apparent upon understanding the disclosure of this application.

[0020] Throughout the specification, when an element (such as a layer, region, or substrate) is described as being "on" another element, "connected to" another element, "bonded to" another element, "on" another element, or "covering" another element, it may be directly "on" another element, "connected to" another element, "bonded to" another element, "on" another element, or "covering" another element, or there may be one or more other elements in between. In contrast, when an element is described as being "directly on" another element, "directly connected to" another element, "directly bonded to" another element, "directly on" another element, or "directly covering" another element, there may be no other elements in between.

[0021] As used herein, the term “and / or” includes any one of the relevant items listed and any combination of any two or more items.

[0022] Although terms such as “first,” “second,” and “third” may be used herein to describe individual components, assemblies, regions, layers, or parts, these components, assemblies, regions, layers, or parts are not limited by these terms. Rather, these terms are used only to distinguish one component, assembly, region, layer, or part from another. Therefore, without departing from the teachings of the examples described herein, the first component, assembly, region, layer, or part referred to as the second component, assembly, region, layer, or part may also be referred to as the second component, assembly, region, layer, or part.

[0023] For ease of description, spatial relation terms such as “above,” “upper,” “below,” and “lower” are used herein to describe the relationship between one element and another, as shown in the accompanying drawings. Such spatial relation terms are intended to include not only the orientation depicted in the drawings but also different orientations of the device during use or operation. For example, if the device in the drawings is flipped, an element described as being “above” or “upper” relative to another element will subsequently be “below” or “lower” relative to that other element. Therefore, the term “above” includes both “above” and “below” orientations depending on the spatial orientation of the device. The device may also be positioned in other ways (e.g., rotated 90 degrees or in other orientations), and the spatial relation terms used herein will be interpreted accordingly.

[0024] The terminology used herein is for the purpose of describing various examples only and is not intended to limit this disclosure. Unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. The terms “comprising,” “including,” and “having” enumerate the stated features, quantities, operations, components, elements, and / or combinations thereof, but do not exclude the presence or addition of one or more other features, quantities, operations, components, elements, and / or combinations thereof.

[0025] Variations in the shapes shown in the accompanying drawings may occur due to manufacturing techniques and / or tolerances. Therefore, the examples described herein are not limited to the specific shapes shown in the accompanying drawings, but include changes in shape that may occur during manufacturing.

[0026] The features of the examples described herein can be combined in various ways that will be apparent upon understanding the disclosure of this application. Furthermore, although the examples described herein have a wide variety of constructions, other constructions are possible, as will be apparent upon understanding the disclosure of this application.

[0027] According to a first aspect of the present invention, a top cover assembly 1 is provided, such as Figures 1 to 3 As shown, the roof assembly 1 in this embodiment includes an interior trim layer 11, a transition layer 12, an energy-absorbing layer 13, a substrate layer 14, and a protective layer 15 stacked sequentially. The interior trim layer 11, transition layer 12, energy-absorbing layer 13, substrate layer 14, and protective layer 15 are formed into an integral structure by a molding process. Furthermore, the substrate layer 14 (by molding) has a first connecting portion 141, and the roof assembly 1 is assembled to the vehicle body 2 via the first connecting portion 141. When the roof assembly 1 is assembled to the vehicle body 2, along the height direction of the vehicle body 2, the interior trim layer 11 is located at the innermost side of the roof assembly 1, and the protective layer 15 is located at the outermost side of the roof assembly 1.

[0028] Since the top cover assembly 1 is a one-piece structure, it can eliminate the need for connectors and adhesives required during the assembly of transmission machinery, and can also avoid the occurrence of interlayer peeling, abnormal noise and other issues caused by vibration and temperature changes during use.

[0029] Specifically, in this embodiment, the interior trim layer 11 is formed as a knitted layer, a leather layer, or a hemp fiber layer, and the thickness of the interior trim layer 11 is 0.8mm to 1.2mm. Further, the interior trim layer 11 is actually formed as the interior headliner surface of the vehicle, and after being molded and cured on the inside of the transition layer 12, it does not require further pasting or covering processes. When the interior trim layer 11 is formed as a knitted layer, passenger car-specific knitted fabric can be used; when the interior trim layer 11 is formed as a leather layer, microfiber leather can be used; when the interior trim layer 11 is formed as a hemp fiber layer, hemp fiber textured panel can be used. All of these materials have good decorative properties and tactile feel, and have good composite compatibility with the transition layer 12 under molding conditions.

[0030] In this embodiment, the transition layer 12 is formed as a composite structural layer composed of fiberglass felt and structural adhesive, with the structural adhesive filling the pores and fiber surface of the fiberglass felt; the thickness of the transition layer 12 is 0.3mm to 0.5mm. Specifically, the fiberglass felt is a microporous flexible fiberglass felt, and the structural adhesive is a modified structural adhesive, so that the structural adhesive can fill the pores and fiber surface of the fiberglass felt to form a flexible thin-layer structure. The transition layer 12 is located between the aforementioned interior layer 11 and the aforementioned energy-absorbing layer 13, and it can solve the problems of stress peeling and thermal expansion and contraction cracking between the interior layer 11 and the energy-absorbing layer 13. At the same time, the transition layer 12 can also balance the molding pressure to prevent defects from occurring on the surface of the interior layer 11.

[0031] In this embodiment, the energy-absorbing layer 13 is formed as a polyurethane foam layer or a polyester honeycomb composite core layer; the thickness of the energy-absorbing layer 13 is 10mm~20mm, and the density of the energy-absorbing layer 13 is 45 kg / m³~70 kg / m³. When the energy-absorbing layer 13 is formed as a polyurethane foam layer, the polyurethane foam layer is specifically composed of closed-cell modified rigid polyurethane foam, which has a closed microporous structure inside, thereby giving the energy-absorbing layer 13 good heat insulation, sound insulation, and buffering energy absorption effects. In addition, when the energy-absorbing layer 13 is formed as a polyester honeycomb composite core layer, the polyester honeycomb composite core layer is specifically made of polyethylene terephthalate, which is formed as a honeycomb structure, thereby playing the role of heat insulation, sound insulation, and buffering energy absorption. Furthermore, the polyester honeycomb composite core layer has low density and high compressive strength.

[0032] In this embodiment, the matrix layer 14 is formed as a continuous long glass fiber reinforced thermoplastic composite material layer (or it can be formed as a thin carbon fiber hybrid reinforcement material layer), and the thickness of the matrix layer 14 is 2mm~3mm. Continuous long glass fiber reinforced thermoplastic composite material is an existing material in the art, possessing high strength, high modulus, and excellent impact resistance, enabling the roof assembly 1 to meet the load-bearing requirements of the vehicle. Furthermore, the matrix layer 14 is internally provided with reinforcing ribs, which can be formed as longitudinal reinforcing ribs extending along the length direction of the matrix layer 14. Multiple reinforcing ribs are parallel and evenly spaced to improve the stiffness and bending strength of the matrix layer 14.

[0033] Furthermore, a first connecting portion 141 is formed at the end face of the substrate layer 14. The first connecting portion 141 is formed as a countersunk hole structure, and the inner sidewall of the countersunk hole is formed with internal threads. The opening of the countersunk hole is located at the end face of the substrate layer 14. It should be noted that the reinforcing rib and the first connecting portion 141 are integrally formed with the substrate layer 14 by a molding process (for example, the countersunk hole in the first connecting portion 141 can be formed by pre-embedding a threaded insert during molding). In addition, there are no specific restrictions on the specific distribution and specifications of the countersunk holes in the first connecting portion 141, which can be determined comprehensively based on the actual situation, such as the specifications of the substrate layer 14.

[0034] In this embodiment, the protective layer 15 is formed as an alkali-free glass fiber layer or a basalt fiber reinforced modified polypropylene prepreg layer, and the thickness of the protective layer 15 is 1.2mm to 1.8mm. Furthermore, the outer surface of the protective layer 15 is pre-fabricated with a matte substrate to meet the requirements of electrophoretic coating, meaning that electrophoretic coating can be directly applied to the outer surface of the protective layer 15, thereby ensuring that the outer surface of the top cover assembly 1 is the same color as the outer surface of the vehicle body 2.

[0035] According to the roof assembly 1 of the present invention, it includes an interior layer 11, a transition layer 12, an energy-absorbing layer 13, a base layer 14, and a protective layer 15 stacked sequentially, which can meet the basic functions required by the roof assembly 1 of the vehicle, such as protection, heat insulation, sound insulation, and buffering and energy absorption. In addition, the above five structural layers are formed into an integral structure by molding process, that is, the roof assembly 1 is an integral structure, which does not require subsequent assembly, greatly reducing the number of parts and assembly process. Based on the reduction of assembly parts and the high integration of the structure of the roof assembly 1, the weight of the roof assembly 1 is effectively reduced.

[0036] According to a second aspect of the present invention, a vehicle is provided, which includes the aforementioned roof assembly 1. The vehicle body 2 has a second connecting portion 21 corresponding to the first connecting portion 141, thereby enabling efficient assembly of the roof assembly 1 to the vehicle using fasteners such as bolts, and ensuring stability after assembly.

[0037] Finally, it should be noted that the above-described embodiments are merely specific implementations of this application, used to illustrate the technical solutions of this application, and not to limit them. The protection scope of this application is not limited thereto. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features, within the technical scope disclosed in this application. Such modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be covered within the protection scope of this application. Therefore, the protection scope of this application should be defined by the protection scope of the claims.

Claims

1. A roof assembly characterized by, The top cover assembly includes an interior trim layer, a transition layer, an energy-absorbing layer, a substrate layer, and a protective layer stacked sequentially; the interior trim layer, the transition layer, the energy-absorbing layer, the substrate layer, and the protective layer are formed into an integral structure by a molding process; the substrate layer has a first connecting portion.

2. The header assembly of claim 1, wherein, The interior trim layer is formed as a knitted layer, a leather layer, or a linen fiber layer; the thickness of the interior trim layer is 0.8mm to 1.2mm.

3. The header assembly of claim 1, wherein, The transition layer is formed as a composite structural layer composed of fiberglass mat and structural adhesive, wherein the structural adhesive fills the pores of the fiberglass mat and the fiber surface; the thickness of the transition layer is 0.3mm~0.5mm.

4. The header assembly of claim 1, wherein, The energy-absorbing layer is formed as a polyurethane foam layer or a polyester honeycomb composite core layer; the thickness of the energy-absorbing layer is 10mm~20mm; and the density of the energy-absorbing layer is 45 kg / m³~70kg / m³.

5. The header assembly of claim 1, wherein, The matrix layer is formed as a continuous long glass fiber reinforced thermoplastic composite material layer, and the thickness of the matrix layer is 2mm~3mm.

6. The header assembly of claim 5, wherein, The substrate layer has internal reinforcing ribs; the first connecting portion is formed at the end face of the substrate layer.

7. The header assembly of claim 6, wherein, The first connecting part is formed as a countersunk hole structure, the inner sidewall of the countersunk hole is formed with internal threads, and the opening of the countersunk hole is located at the end face of the substrate layer.

8. The header assembly of claim 1, wherein, The protective layer is formed as an alkali-free glass fiber layer or a basalt fiber reinforced modified polypropylene prepreg layer, and the thickness of the protective layer is 1.2mm~1.8mm.

9. A vehicle characterized by comprising: The vehicle includes a roof assembly as claimed in any one of claims 1 to 8.

10. The vehicle of claim 9, wherein, The vehicle body has a second connecting portion corresponding to the first connecting portion.

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