Carbon fiber reinforced sunroof injection molded rail composite load bearing

Abstract

The utility model provides a carbon fiber reinforced sunroof injection rail composite bearing, including sunroof frame body, the sunroof frame body is integrative injection moulding structure, its section sets up polytetrafluoroethylene layer, carbon fiber layer and injection layer gradually from outside to inside, the sunroof frame body is integrative and sets up the limit slot, the sealing strip installation groove, the mechanical assembly installation groove, the front rack slot, the sunshade curtain groove, the interior decoration clamping groove, the rear sunshade curtain clamping groove, the rear rack slot and the sunroof slide, the utility model discloses through multi -material composite structure, give both strength and wear -resisting double demand frame body adopts the three -layer composite structure of " polytetrafluoroethylene layer + carbon fiber layer + injection layer", realizes the accurate matching of function and performance: the outer polytetrafluoroethylene layer is covered the sliding contact area of sunroof slide, utilizes its low friction characteristic and reduces the friction resistance when sunroof opening and closing, avoids the abrasion and the abnormal sound caused by high -frequency contact.

Description

Technical Field

[0001] This utility model relates to the field of automotive parts technology, specifically to a carbon fiber reinforced sunroof injection molded guide rail composite load-bearing component. Background Technology

[0002] The sunroof frame is a core connector that links the sunroof glass, drive components, sealing structure, and vehicle body. It needs to be adapted to the vibration environment during vehicle operation, the dynamic requirements of frequent opening and closing of the sunroof, and the sealing and protection scenarios in rainy and snowy weather. Current traditional sunroof frames have significant limitations in design and material application: First, the material combination is limited, relying mainly on pure injection-molded substrates or simple metal sandwich structures, without differentiated design for "load-bearing strength" and "local wear resistance," resulting in insufficient overall deformation resistance of the frame, and high-frequency contact parts such as tracks are prone to wear due to excessive friction; Second, the structural design is fragmented, with functional areas such as limiting structures, sealing strip mounting positions, and rack assembly grooves often being independently processed and then spliced, which not only increases production steps but also easily leads to decreased assembly accuracy due to splicing gaps, affecting the smoothness of sunroof opening and closing; Third, detailed design is lacking, the inner wall of the sealing strip mounting groove lacks an anti-displacement structure, and the sealing strip is prone to falling off or shifting due to vibration during long-term use, leading to sealing failure; areas with concentrated stress, such as sunroof tracks and mechanical component mounting grooves, lack reinforced structures, and are prone to local dents or cracks under load impact; the tooth shape design of the rack groove is not adapted to the transmission requirements of the drive components, easily causing engagement jamming. These problems not only reduce the user experience of the sunroof, but also shorten the overall lifespan of the frame, making it difficult to meet the design standards for high reliability and long lifespan of automotive parts. Utility Model Content

[0003] The purpose of this utility model is to address the shortcomings of existing technologies by proposing a carbon fiber reinforced sunroof injection-molded guide rail composite load-bearing component, including a sunroof frame body. The sunroof frame body is an integral injection-molded structure, and its cross-section is provided with a polytetrafluoroethylene layer, a carbon fiber layer, and an injection-molded layer from the outside to the inside. The sunroof frame body integrates a limit groove, a sealing strip mounting groove, a mechanical component mounting groove, a front rack groove, a sunshade groove, an interior trim slot, a rear sunshade slot, a rear rack groove, and a sunroof track.

[0004] The sunroof frame body has an interior trim slot on one side of its bottom surface, a sunshade slot above the interior trim slot, a front rack slot above the sunshade slot, and the front rack slot and sunshade slot are located on the top surface of the sunroof frame body. A sunroof track is located on one side of the front rack slot, a mechanical component mounting slot is located on one side of the sunroof track, a sealing strip mounting slot is located above the sunroof track, a rear rack slot is located on one side of the sunroof track, a rear sunshade slot is located on one side of the rear rack slot, and a limiting groove is located above the rear sunshade slot.

[0005] The reinforcing ribs are respectively installed on the inner walls of both sides of the sunroof track and the bottom edge area of ​​the mechanical component mounting groove; the cross-section of the reinforcing ribs is rectangular, with a width of 1.8±0.2mm, a height of 2.5±0.3mm, and a spacing of 18±2mm between adjacent reinforcing ribs.

[0006] The thickness of the polytetrafluoroethylene layer is 0.3±0.05mm.

[0007] The thickness of the carbon fiber layer is 0.8±0.1mm.

[0008] The sealing strip mounting groove has a U-shaped cross-section, with a groove width of 8±0.5mm and a groove depth of 6±0.5mm. The inner wall of the sealing strip mounting groove is provided with anti-slip ridges with a semi-circular cross-section, the ridge height of which is 1.0±0.2mm and the circumferential spacing is 4±0.5mm.

[0009] Both the front rack groove and the rear rack groove are provided with involute tooth structure, with a tooth height of 2.2mm, a number of 25 teeth, and a tooth pitch error of ≤0.05mm.

[0010] The beneficial effects of this utility model are as follows: 1. Multi-material composite structure, taking into account both strength and wear resistance. The frame body adopts a three-layer composite structure of "polytetrafluoroethylene layer + carbon fiber layer + injection molding layer", which achieves a precise match between function and performance: the outer polytetrafluoroethylene layer is specifically designed to cover the sliding contact area of ​​the sunroof track, using its low friction characteristics to reduce frictional resistance when the sunroof is opened and closed, and avoid wear and abnormal noise caused by high-frequency contact; the middle carbon fiber layer provides core mechanical support for the frame, enhances the overall tensile and bending resistance, and copes with vehicle vibration and load impact; the inner injection molding layer uses glass fiber reinforced material, taking into account both formability and impact resistance, ensuring the connection stability between the frame and the body and various components, and solving the contradiction of "insufficient strength" or "lack of wear resistance" of traditional single materials.

[0011] 2. Targeted Reinforcement Rib Design Enhances Load-Bearing Capacity in Key Components: Rectangular reinforcement ribs are specifically designed for two areas of concentrated stress: the inner wall of the sunroof track (bearing the pressure of glass sliding) and the bottom of the mechanical component mounting slot (bearing the weight of the drive components). This design directly improves the local structure's resistance to compression and deformation, preventing problems such as track denting and mounting slot cracking during long-term load-bearing, ensuring stable operation of the drive components and sunroof glass, and extending the durability of key frame components.

[0012] 3. Integrated Structure: Simplifies Assembly and Improves Precision. The frame body is manufactured using a one-piece injection molding process, integrating functional areas such as limiting grooves, sealing strip mounting grooves, mechanical component mounting grooves, front rack grooves, rear rack grooves, sunshade grooves, and interior trim slots onto a single structure, eliminating the need for subsequent splicing and processing. This reduces assembly steps compared to traditional fragmented structures, avoiding errors caused by multiple alignments. Furthermore, the integrated structure ensures the relative positional accuracy of each functional area, enabling rapid and precise assembly of components such as sealing strips, racks, and sunshades, thus improving the overall assembly efficiency and operational stability of the sunroof system.

[0013] 4. Detailed design optimization enhances sealing and transmission reliability. The sealing strip mounting groove adopts a U-shaped structure with semi-circular anti-slip ridges on the inner wall. The U-shaped groove enables quick positioning of the sealing strip, while the anti-slip ridges increase the friction between the sealing strip and the groove wall, preventing the sealing strip from shifting or falling off due to vehicle vibration. This strengthens the stability of the sealing structure and avoids air and water leakage problems. The front and rear rack grooves have built-in involute teeth that can form a precise mesh with the drive gear, reducing transmission backlash and ensuring the stroke accuracy during sunroof opening and closing, avoiding jamming or stroke deviation caused by mismatched teeth.

[0014] 5. One-piece molding process ensures structural integrity and consistency. The entire frame adopts one-piece injection molding technology, which eliminates the connection gaps between different parts compared with the traditional spliced ​​structure. This not only improves the overall rigidity of the frame, but also reduces the risk of corrosion caused by gaps (such as rainwater seeping into the gaps and causing rust). At the same time, one-piece molding can ensure the consistency of structural dimensions of each batch of products, reduce assembly and adaptation problems caused by differences in parts, and improve the stability of production quality. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model.

[0016] Figure 2 This is a schematic diagram of the structural layers of the skylight frame body of this utility model.

[0017] In the diagram: 1. Limiting groove, 2. Sealing strip mounting groove, 3. Mechanical component mounting groove, 4. Front rack groove, 5. Sunshade groove, 6. Interior trim clip groove, 7. Rear sunshade clip groove, 8. Rear rack groove, 9. Sunroof track, 10. Sunroof frame body, 101. Polytetrafluoroethylene layer, 102. Carbon fiber layer, 103. Injection molding layer. Detailed Implementation

[0018] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent. To better illustrate this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0019] Example 1, as shown in the figure: A carbon fiber reinforced sunroof injection-molded guide rail composite load-bearing component includes a sunroof frame body 10; the sunroof frame body 10 is an integral injection-molded structure, and its cross-section is provided with a polytetrafluoroethylene layer 101, a carbon fiber layer 102 and an injection-molded layer 103 from the outside to the inside; the sunroof frame body 10 is integrated with a limiting groove 1, a sealing strip mounting groove 2, a mechanical component mounting groove 3, a front rack groove 4, a sunshade groove 5, an interior trim slot 6, a rear sunshade slot 7, a rear rack groove 8 and a sunroof track 9. The sunroof frame body 10 has an interior trim slot 6 on one side of its bottom end face. Above the interior trim slot 6 is a sunshade slot 5, and above the sunshade slot 5 is a front rack slot 4. The front rack slot 4 and the sunshade slot 5 are located on the top surface of the sunroof frame body 10. A sunroof track 9 is located on one side of the front rack slot 4. A mechanical component mounting slot 3 is located on one side of the sunroof track 9. A sealing strip mounting slot 2 is located above the sunroof track 9. A rear rack slot 8 is located on one side of the sunroof track 9. A rear sunshade slot 7 is located on one side of the rear rack slot 8. A limiting slot 1 is located above the rear sunshade slot 7. Reinforcing ribs are correspondingly located on the inner walls of both sides of the sunroof track 9 and at the bottom edge of the mechanical component mounting slot 3. The reinforcing ribs have a rectangular cross-section with a width of 1.8±0.2mm and a height of 2.5±0.3mm, and the spacing between adjacent reinforcing ribs is 18±2mm. The thickness of the polytetrafluoroethylene layer 101 is 0.3±0.05mm. The thickness of the carbon fiber layer 102 is 0.8±0.1mm. The sealing strip mounting groove 2 has a U-shaped cross-section, with a groove width of 8±0.5mm and a groove depth of 6±0.5mm. The inner wall of the sealing strip mounting groove 2 is provided with semi-circular anti-slip ridges, with a ridge height of 1.0±0.2mm and a circumferential spacing of 4±0.5mm. Both the front rack groove 4 and the rear rack groove 8 are provided with involute tooth structures, with a tooth height of 2.2mm, 25 teeth, and a tooth pitch error ≤0.05mm.

[0020] In this utility model: 1. Layer structure details Polytetrafluoroethylene layer 101: Made of suspension polymerized PTFE material, with a thickness of 0.3±0.05mm, covering only the sliding contact area (width 25mm) of the sunroof track 9; its static friction coefficient ≤0.05, dynamic friction coefficient ≤0.04, and applicable temperature range -40℃~120℃, suitable for extreme automotive operating conditions; Carbon fiber layer 102: Made of 3K plain weave carbon fiber cloth (area density 200g / m²), impregnated with modified PP resin (resin content 40±5%), and integrally molded with injection molding layer 103, with a thickness of 0.8±0.1mm; the tensile strength of this layer is ≥320MPa, which improves the frame's resistance to deformation by 60% compared to pure PP injection molded parts; Injection layer 103: Made of 25% glass fiber reinforced PP material, with notched impact strength ≥8kJ / m², flexural strength ≥45MPa, melt flow index 12g / 10min (190℃, 2.16kg), meeting the requirements for injection molding performance and impact resistance.

[0021] 2. Functional Structure Details Reinforcing rib structure: The cross section is rectangular (width 1.8±0.2mm, height 2.5±0.3mm), with an adjacent spacing of 18±2mm, and distributed on the inner wall of the sunroof slide 9 and the bottom of the mechanical component mounting groove 3 (3); so that the lateral bearing capacity of the sunroof slide 9 area is ≥150N; Sealing strip installation groove 2: "U" shaped structure (groove width 8±0.5mm, groove depth 6±0.5mm), with semi-circular anti-slip ridges on the inner wall (height 1.0±0.2mm, spacing 4±0.5mm); after assembling the EPDM sealing strip, the sealing pressure is ≥0.3MPa; Front rack slot 4 and rear rack slot 8: involute tooth profile with module m=1.0, tooth height 2.2mm, number of teeth 25, tooth pitch error ≤0.05mm; when meshing with the drive gear, the transmission clearance ≤0.1mm, and the sunroof stroke accuracy ±0.5mm.

[0022] 3. Performance verification results This component has undergone automotive parts bench testing: Vibration fatigue: After 1000 hours of testing at 10-200Hz and 2g acceleration, the frame showed no cracks and the deformation was ≤0.2mm. Opening and closing life: Simulated 10 opening and closing cycles per day, continuous test 18,000 times (equivalent to 5 years of use), slide wear ≤0.03mm, transmission without jamming; Sealing performance: IPX5 level test (30kPa water pressure spray), no leakage.

[0023] This utility model proposes a compact carbon fiber reinforced sunroof injection-molded guide rail composite load-bearing component. The multi-material composite structure balances strength and wear resistance. The frame body adopts a three-layer composite structure of "PTFE layer 101 + carbon fiber layer 102 + injection-molded layer 103," achieving a precise match between function and performance: the outer PTFE layer 101 specifically covers the sliding contact area of ​​the sunroof track 9, utilizing its low-friction characteristics to reduce frictional resistance during sunroof opening and closing, avoiding wear and abnormal noise caused by high-frequency contact; the middle carbon fiber layer 102 provides core mechanical support for the frame, enhancing overall tensile and bending resistance to cope with vehicle vibration and load impact; the inner injection-molded layer 103 uses glass fiber reinforced material, balancing formability and impact resistance, ensuring the connection stability between the frame and the vehicle body and other components, thus solving the contradiction of "insufficient strength" or "lack of wear resistance" in traditional single-material systems. Targeted reinforcement design enhances the load-bearing capacity of key components. Rectangular reinforcement structures are specifically designed for the two stress-concentrated areas: the inner wall of the sunroof track 9 (bearing the pressure of glass sliding) and the bottom of the mechanical component mounting slot 3 (bearing the weight of the drive components). This design directly improves the local structure's resistance to compression and deformation, preventing problems such as track denting and mounting slot cracking during long-term load-bearing, ensuring stable operation of the drive components and sunroof glass, and extending the durability of key frame components. Integrated structure simplifies assembly and improves precision. The frame body is integrated into a single structure using a one-piece injection molding process, integrating functional areas such as the limiting groove 1, sealing strip mounting slot 2, mechanical component mounting slot 3, front rack groove 4, rear rack groove 8, sunshade groove 5, and interior trim slot 6 onto a single structure, eliminating the need for subsequent splicing. This reduces assembly steps in traditional fragmented structures, avoiding errors caused by multiple alignments; furthermore, the integrated structure ensures the relative positional accuracy of each functional area, enabling quick and precise assembly of components such as sealing strips, racks, and sunshades, improving the overall assembly efficiency and operational stability of the sunroof system. Detailed design optimization enhances sealing and transmission reliability. The sealing strip mounting groove 2 features a U-shaped structure with semi-circular anti-slip ridges on the inner wall. This allows for quick positioning of the sealing strip via the U-shaped groove, while the anti-slip ridges increase friction between the sealing strip and the groove wall, preventing displacement or detachment due to vehicle vibration. This strengthens the stability of the sealing structure and prevents air and water leaks. The front rack groove 4 and rear rack groove 8 incorporate involute teeth, allowing for precise engagement with the drive gear, reducing transmission backlash, ensuring stroke accuracy during sunroof opening and closing, and preventing jamming or stroke deviation due to tooth mismatch. Integrated molding ensures structural integrity and consistency. The entire frame utilizes integrated injection molding technology. Compared to traditional spliced ​​structures, this eliminates gaps between different components, improving overall frame rigidity and reducing corrosion risks caused by gaps (such as rainwater seepage leading to rust). Furthermore, integrated molding ensures dimensional consistency across batches, reducing assembly and fitting issues caused by component differences and improving production quality stability.

[0024] Finally, it should be noted that the above embodiments were selected and described in detail to better illustrate the technical solution of this utility model patent, and are not intended to limit oneself to the details shown. Modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model without departing from the spirit and scope of this utility model should be covered within the scope of the claims of this utility model.

Claims

1. A composite load-bearing component for injection-molded sunroof guide rails, characterized in that... The system includes a sunroof frame body (10); the sunroof frame body (10) is an integral injection-molded structure, and its cross-section is provided with a polytetrafluoroethylene layer (101), a carbon fiber layer (102) and an injection-molded layer (103) from the outside to the inside; the sunroof frame body (10) is provided with a limit groove (1), a sealing strip mounting groove (2), a mechanical component mounting groove (3), a front rack groove (4), a sunshade groove (5), an interior trim slot (6), a rear sunshade groove (7), a rear rack groove (8) and a sunroof track (9); the bottom end face of the sunroof frame body (10) is provided with an interior trim slot (6), the interior trim slot (6) is provided with a sunshade groove (5) above it, the sunshade groove (5) is provided with a front rack groove (4) above it, and the front rack groove (4) and the sunshade groove (5) are located on the sunroof frame body. On the top surface of the body (10), a sunroof slide (9) is provided on one side of the front rack groove (4), a mechanical component mounting groove (3) is provided on one side of the sunroof slide (9), a sealing strip mounting groove (2) is provided above the sunroof slide (9), a rear rack groove (8) is provided on one side of the sunroof slide (9), a rear sunshade clip groove (7) is provided on one side of the rear rack groove (8), and a limiting groove (1) is provided above the rear sunshade clip groove (7); the sunroof frame body (10) is also provided with a reinforcing rib structure, which is correspondingly set on the inner walls of both sides of the sunroof slide (9) and the bottom edge area of ​​the mechanical component mounting groove (3). The cross section of the reinforcing rib is rectangular, with a width of 1.8±0.2mm and a height of 2.5±0.3mm, and the spacing between adjacent reinforcing ribs is 18±2mm.

2. The carbon fiber reinforced sunroof injection molded guide rail composite load-bearing component according to claim 1, characterized in that: The thickness of the polytetrafluoroethylene layer (101) is 0.3±0.05mm.

3. The carbon fiber reinforced sunroof injection molded guide rail composite load-bearing component according to claim 1, characterized in that: The thickness of the carbon fiber layer (102) is 0.8±0.1mm.

4. The carbon fiber reinforced sunroof injection molded guide rail composite load-bearing component according to claim 1, characterized in that: The sealing strip mounting groove (2) has a U-shaped cross section with a groove width of 8±0.5mm and a groove depth of 6±0.5mm. The inner wall of the sealing strip mounting groove (2) is provided with anti-slip ridges with a semi-circular cross section, the ridge height is 1.0±0.2mm and the circumferential spacing is 4±0.5mm.

5. The carbon fiber reinforced sunroof injection molded guide rail composite load-bearing component according to claim 1, characterized in that: Both the front rack groove (4) and the rear rack groove (8) are provided with involute tooth structures, with a tooth height of 2.2 mm, a number of 25 teeth, and a tooth pitch error of ≤0.05 mm.

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