Vehicle roof assembly with integrated RF transparency for electronic module consolidation

Abstract

To provide a vehicle roof assembly that enables the integration of overhead electrical modules and components directly into the roof structure by the use of high frequency (RF) transparent polymer materials.SOLUTION: An assembly enables the integration of overhead electrical modules and components, including antennae, directly into the roof structure, facilitating clear communication with external devices and satellites. The design incorporates a membrane effect for enhanced occupant protection during impacts, and the use of integrated foams between the exterior roof and an interior headliner 110 improves thermal and acoustic insulation. An assembly process is streamlined by pre-populating the roof with electrical components 116, allowing for a single-unit installation and the potential for full automation in the assembly line. Roof's polymer construction also offers enhanced dent resistance, color options, and inherent corrosion resistance, while meeting safety standards such as the Head Injury Criterion (HIC) values.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to vehicle structures and, more particularly, to an integrated roof assembly for a vehicle that incorporates radio frequency (RF) transparent materials to enable integration of overhead electrical modules and components. [Background technology]

[0002] Traditional vehicle roof structures typically involve the use of metal or glass materials, which provide structural integrity and protection from environmental elements. However, these materials have limitations when it comes to integrating modern vehicle technology, particularly technology requiring radio frequency (RF) transmission and reception. While providing structural rigidity, metal roofs act as a barrier to RF signals, necessitating the placement of antennas and other communication devices externally. On the other hand, glass roofs allow for RF transparency, but present challenges in integrating electronic components without compromising aesthetic appeal and visibility.

[0003] Furthermore, assembling electronic modules and components in vehicles with traditional roofs often requires a complex and time-consuming process involving multiple connections, which can present ergonomic challenges for assembly workers. The overhead installation process can be particularly labor-intensive and limit opportunities for automation within the assembly line. Furthermore, traditional roof structures may not adequately address the need for thermal and acoustic insulation, occupant protection, and compliance with safety regulations, such as head impact standards. Summary of the Invention

[0004] Some examples of the present disclosure provide vehicle roof assemblies that utilize radio frequency (RF) transparent polymer materials to enable the integration of overhead electrical modules and components directly into the roof structure. This approach addresses the limitations of traditional metal and glass roofs by allowing RF signals to pass through the roof material, thereby facilitating the integration of electronic systems and antennas that require a clear path to communicate with external devices and satellites.

[0005] Some examples of vehicle roof assemblies herein include high-strength polymer blends, such as polycarbonate (PC), acrylonitrile butadiene styrene (ABS), or acrylonitrile styrene acrylate (ASA), selected for their RF transparency and structural properties. In some instances, these materials provide adequate strength for impact resistance, stiffness for noise, vibration, and harshness (NVH) control, and compliance with head impact regulations. In some instances, the incorporation of these polymers allows the roof to be opaque, thereby reducing solar transmission and reducing the thermal load on the cabin, also improving the thermal comfort of vehicle occupants.

[0006] Some examples allow the ability to pre-fit selected electrical components onto the roof structure, which can be installed as a single unit during vehicle assembly. This can result in increased efficiency for assemblers and reduced assembly time and labor. In some examples, the vehicle roof assembly can be pre-assembled on a horizontal surface, thereby eliminating the need for an overhead installation process and allowing for full automation of roof subsystem assembly.

[0007] Some examples further improve thermal and acoustic insulation by using foam between the exterior polymer roof and the interior headliner. The polymer roof structure provides excellent acoustic insulation properties to reduce airborne noise within the cabin.

[0008] In conventional vehicle designs, the headliner is typically a separate component from the roof and is designed to compress and absorb energy during an impact. This compression is the primary means by which the headliner reduces the force of the impact to protect the occupant's head, and requires a certain thickness or space between the headliner and the roof to provide sufficient cushioning.

[0009] In contrast, some examples herein utilize polymer roof structures that exhibit a "membrane effect." The membrane effect of a polymer roof contributes to occupant crash protection by allowing the roof (e.g., an outer RF-transparent polymer roof panel) and head dome (e.g., defined in an inner substrate assembly) to stroke (or move) together through flexure, in contrast to conventional headliners that rely solely on compression. In other words, the term "stroke together through flexure" in the context of a vehicle roof and head dome refers to the way the roof material and inner headliner (often referred to as a head dome) respond to an impact, such as an occupant's head contacting the roof during a crash. In some examples, the outer RF-transparent polymer roof panel and inner substrate assembly can stroke together during an impact.

[0010] The polymer material of the roof itself has a certain degree of flexibility, allowing it to flex or bend to a certain extent. Upon impact, the polymer roof and head dome move together as a single unit, bending inward and absorbing the impact energy. This flexing of the outer roof substrate, combined with the head dome, provides an additional mechanism for energy absorption. One advantage of this design is that it reduces the need for a thick cushioning layer between the headliner and roof, since the roof material itself contributes to impact protection. This allows for a thinner overall roof structure, allowing for more headroom in the vehicle and potentially reducing the weight of the roof assembly. The disclosed example still meets safety standards, such as Head Injury Criteria (HIC) values, specified by regulations such as Federal Motor Vehicle Safety Standard (FMVSS) 201U, which governs upper interior head impact protection.

[0011] In some instances, when an object, such as a passenger's head, impacts the roof, the membrane effect allows the polymer material to deflect, absorb, and dissipate energy over a wider area. This reduces the force transmitted to the object—in this case, the passenger's head—potentially reducing injury. The flexible nature of polymer materials means they can deform to some degree without breaking or fracturing. This conformability can help absorb impact energy and provide a cushioning effect. Traditional vehicle roofs may require thicker, more rigid materials to provide structural integrity and impact protection. The membrane effect of polymer roofs allows for thinner construction while still meeting safety standards, since the material itself can contribute to energy absorption. Vehicles must comply with safety standards, such as Federal Motor Vehicle Safety Standard (FMVSS) 201U, which sets standards for upper interior head impact protection. The membrane effect of polymer roofs can help meet these standards by allowing the roof and headliner to stroke or move together to effectively absorb impact energy. In some instances, the membrane effect can provide more design flexibility, as the roof can be designed to have varying degrees of flexibility and stiffness in different areas, optimizing it for both impact protection and overall vehicle performance. In some instances, the membrane effect of a polymer roof structure can enhance impact protection by allowing the roof to flex and absorb energy during an impact, reducing the severity of occupant injuries and providing more design options for vehicle manufacturers.

[0012] Some exemplary assemblies of roof structures disclosed herein benefit from part reduction because rib features and shapes can also be molded into the polymer geometry, thereby eliminating the need for additional metal roof crossbows. Polymer materials offer excellent dent resistance, superior craftsmanship with molded datum pins, moldability of sharper features, a variety of color options, and inherent corrosion resistance.

[0013] Some examples seek to provide a vehicle roof assembly that not only improves the integration and performance of electronic systems within a vehicle, but also provides improved manufacturing efficiencies, vehicle safety, and occupant comfort. [Brief explanation of the drawings]

[0014] Throughout the drawings, reference numbers may be reused to indicate correspondence between referenced elements. The drawings are provided to illustrate examples of the subject matter described herein and not to limit the scope thereof.

[0015] [Figure 1] 1 is a perspective, partially cross-sectional view of a vehicle roof assembly installed on a vehicle, according to some examples.

[0016] [Figure 2A] 1 is a perspective view of an example antenna module and mounting housing for integration with an exterior RF transparent polymer roof panel, showing example pre-mounted electrical components and antennas, according to some examples.

[0017] [Figure 2B] 2B is a side view of the exemplary antenna module and mounting housing of FIG. 2A.

[0018] [Figure 3] FIG. 2 is a component diagram illustrating example electrical components and their connections to systems of a vehicle, including cabin radar and a vehicle computer, according to some examples.

[0019] [Figure 4A] FIG. 1 is an exploded view of an example first vehicle roof subassembly kit showing the outer RF transparent polymer roof panel and associated components such as the ground plate, mounting bracket, and datum block.

[0020] [Figure 4B]FIG. 10 is an exploded view of an example second vehicle roof subassembly kit showing example components of an inner substrate assembly including a wrapped polymer substrate and an insulating layer, according to some examples.

[0021] [Figure 4C] 1 shows a typical first adhesive application pattern for bonding a wrapped polymer substrate to an insulating layer.

[0022] [Figure 5] 1 is a flow diagram of exemplary steps in a method for forming a vehicle roof, according to some examples.

[0023] [Figure 6] 1 provides an enlarged view of an example first vehicle roof subassembly, an example antenna module and mounting housing, an example closure panel, and an example completed vehicle roof assembly, including an example adhesive application pattern for joining the assembly to the vehicle.

[0024] [Figure 7] 1 is a table listing exemplary specifications for various components of an example vehicle roof assembly, according to some examples.

[0025] [Figure 8] FIG. 1 is a process flow diagram illustrating exemplary steps in assembling a vehicle roof, according to some examples. DETAILED DESCRIPTION OF THE INVENTION

[0026] Some examples herein provide a vehicle roof assembly in which a radio frequency (RF) transparent polymer is used as the primary material for the roof structure. This material selection facilitates the integration and consolidation of electrical components that interface with both the interior and exterior of the vehicle's cabin. The roof assembly is designed to be pre-fitted with any desired or required electrical components and installed as a single unit during the vehicle assembly process. In some examples, this approach can provide manufacturing efficiencies and, in some cases, eliminate the need for overhead in-vehicle assembly, thereby providing ergonomic benefits to assembly line workers.

[0027] Roof structures utilize high-strength polymer blends, including, but not limited to, polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA). These materials are selected based on their ability to meet the roof's structural requirements, such as impact resistance, generally quantified by strength; noise, vibration, and harshness (NVH), generally quantified by stiffness; and compliance with head impact regulations, generally quantified by energy absorption capacity. In some instances, the roof's opaque nature helps prevent or reduce solar radiation from penetrating the cabin, thereby reducing heat load and increasing occupant thermal comfort. Second, the roof's opacity allows for the use of foam between the exterior polymer roof and the interior headliner for additional thermal insulation.

[0028] The RF transparent properties of a selected polymer can, in some instances, be important for the integration of various electronic components and antennas, thereby reducing the total number of endpoints and electrical connections within a vehicle. Electrical modules, which typically contain components for interior infotainment systems and external RF communication devices, are traditionally packaged in the insulated space between the exterior roof and interior headliner. These modules require a field of view (FOV) unobstructed by RF opaque materials, necessitating the use of frequency transparent materials for the surrounding substrates and panels.

[0029] By using polymer blends, some examples enable RF transmission from all modules to satellites and other communication devices both inside and outside the vehicle. This integration into a single electronic module can result in reduced parts, consolidation of connectors, and improved performance due to co-location of processing / computing power and reduced losses over cable lengths and connectors.

[0030] In addition to thermal benefits, polymer roof structures with intermediate foam layers can provide enhanced acoustic insulation and absorption properties, for example, significantly reducing stray noise inside the cabin caused by wind and road conditions.

[0031] Occupant crash protection is also a feature in some examples. The membrane effect of the polymer roof, in contrast to a conventional glass roof, allows the roof and head dome to stroke together through flexure of the outer roof substrate. This is due to the polymer material's low modulus of elasticity, which allows for a reduction in cross section between the headliner and roof for the head dome to stroke, in contrast to the compression-only mechanism of a conventional headliner, which requires a greater thickness.

[0032] In some instances, the assembly process is streamlined by consolidating electrical components into larger modules and reducing the number of electrical interconnections, resulting in a three to five times reduction in assembly labor and time. Factory ergonomics is improved because the roof assembly can be pre-assembled upside down and on a horizontal surface, allowing for a layered installation sequence without the need for an overhead installation process. This design also facilitates factory automation by enabling fully automated layered assembly of the roof subsystems.

[0033] Polymer roof designs can include molded-in rib features and shapes, eliminating the need for welded metal roof crossbows used in traditional metal roof construction. This results in reduced sectioning and superior dent resistance compared to the brittle nature of glass roofs. The ability to mold datum pins directly into the panels ensures optimal finish conditions between panels without relying on assembly fixtures. Polymer materials can also offer the convenience of formability, allowing for reduced radii and sharper features or facets compared to traditional stamping processes. Additionally, polymer roofs offer the opportunity for in-resin colorants, eliminating the need for post-process paint, and are inherently corrosion-resistant, reducing the need for additional corrosion protection and post-processing.

[0034] Some examples also address limitations found in conventional vehicle designs, which often feature "shark fin" external antennas for LTE and GNSS communications mounted on a metal roof. The metal roof, typically constructed from aluminum or steel, serves as a ground plane for the antennas and contributes to the vehicle's structural rigidity and stiffness. However, this metal layer also acts as an RF barrier, thereby preventing the integration of interior-facing wireless modules due to its RF-opaque nature. Some examples of polymer roof assemblies disclosed herein seek to overcome this limitation by providing an RF-transparent environment, enabling the integration of both interior and exterior communication modules without the interference issues associated with metal substrates.

[0035] 1 illustrates an example of a vehicle roof assembly 102 installed on the roof of a vehicle. The vehicle roof is generally designated roof 120. The illustrated portion of the vehicle roof assembly 102 is installed adjacent to and at least partially supported by the vehicle's B-pillar 112. The vehicle roof assembly 102 broadly comprises at least two vehicle roof subassemblies, which are further described below in connection with methods for assembling the vehicle roof assembly 102. The first vehicle roof subassembly includes an outer RF-transparent polymer roof panel 104 and, in some examples, is pre-installed with one or more electrical components, generally designated electrical components 116, for installation within the vehicle roof assembly 102. More specific types and configurations of the electrical components 116 are described below.

[0036] The vehicle roof assembly 102 further comprises an inner substrate assembly 106. In some examples, the inner substrate assembly 106 comprises a wrapped polymer substrate 114, one or more insulating layers 108 (e.g., comprising cellular or fibrous foam), and a headliner 110 (or trim). In some examples, the inner substrate assembly 106 defines a shaped free area or zone known as a head dome 118. This area accommodates the occupant's head. In some examples, the head dome 118 of the inner substrate assembly 106 and the outer RF-transparent polymer roof panel 104 can stroke together during an impact, further due to the membrane effect described above.

[0037] 2A-2B show examples of one or more electrical components 116 that may be pre-mounted or pre-installed within the outer RF transparent polymeric roof panel 104 of FIG. 1 prior to installing the outer RF transparent polymeric roof panel 104 within the vehicle roof assembly 102 of FIG. 1. The electrical components 116 may be housed within or located on an antenna module and mounting housing 222. The antenna module and mounting housing 222 may comprise or include a closure panel 602, which is seen more clearly in FIG. 6 below. The antenna module and mounting housing 222 may house and support one or more electrical components 116, such as a satellite communications component 224, a satellite antenna 202, a Long Term Evolution LTE component 232, an LTE antenna 204, a speaker 228, a fan 218, a fan intake duct 226, a connectivity card 214, a processor 220, a Bluetooth low energy component 206, a microphone 216, a map light 212, and a switch 230. Switch 230 may include, for example, a manually operated switch that operates the vehicle hazard lights.

[0038] The satellite communication component 224 may communicate with an external device 208, such as a GNSS satellite, using the satellite antenna 202. The LTE antenna 204 may communicate with an external device 210, such as a 3G, 4G, or 5G LTE network. Other antennas, such as antennas for Wi-Fi and / or Bluetooth connectivity for one or more of the electrical components 116, may also be envisioned.

[0039] As can be seen from the diagram in Figure 2B, in some instances, there is no metal substrate, film, or paint on the exterior surface of the outer RF transparent polymer roof panel 104 of Figure 1, nor on the exterior surfaces of the satellite antenna 202 and LTE antenna 204 that are incorporated within the outer RF transparent polymer roof panel in some instances. This configuration provides a clear, unobstructed view for these components to communicate with their respective external devices, satellites, networks, etc.

[0040] As previously mentioned, some examples described herein therefore seek to address a limitation found in conventional vehicle designs, which often feature "shark fin" external antennas for LTE and GNSS communications mounted on a metal roof. The metal roof, typically constructed from aluminum or steel, serves as a ground plane for the antennas and contributes to the structural rigidity and stiffness of the vehicle. However, this metal layer also acts as an RF barrier, thereby preventing the integration of interior-facing wireless modules due to its RF-opaque nature. Some examples of polymer roof assemblies disclosed herein seek to overcome this limitation by providing an RF-transparent environment, enabling the integration of both interior and exterior communication modules without the interference issues associated with metal substrates.

[0041] 3 shows a diagram of an example of some components of exemplary electrical components 116 of an example vehicle roof assembly 102. The illustrated electrical components 116 include a microphone 216, a switch 230, a satellite antenna 202, a speaker 228, a Bluetooth low energy component 312, one or more LTE antennas 204, a first Wi-Fi / Bluetooth antenna 314, a second Wi-Fi / Bluetooth antenna 316, and a processor 220 (referred to in this figure as the applicant submits the processor).

[0042] The electrical components 116 of the vehicle roof assembly 102 (referred to as Smart Roof in the diagram of FIG. 3 ) are electrically connected to a cabin radar 302 and a vehicle computer 304. The cabin radar 302 may be electrically connected to or include a series of sensors 308 for detecting occupants inside the vehicle or unauthorized entry into the interior of the vehicle. Vehicle occupants may be authenticated by an authentication module 306 based on one or more items of personal data or equipment identification data (e.g., device ID). A connectivity module 310 may check the connectivity status of one or more of the connectivity card 214 of FIG. 2A , the processor 220 of FIG. 2 , the satellite communication component 224 of FIG. 2 , the satellite antenna 202, the LTE component 232, the LTE antenna 204, and / or other electrical components 116.

[0043] 1, in some examples, the vehicle roof assembly 102 broadly comprises at least two vehicle roof subassemblies. The various components for forming or assembling the vehicle roof subassemblies may be provided in the form of one or more kits.

[0044] Referring to FIG. 4A , exemplary components of a first vehicle roof assembly or kit of parts are shown. In the illustrated example, these components include an outer RF-transparent polymer roof panel 104 and a set of other smaller components referred to as piece parts 502 in FIG. 5 . Piece parts 502 may include one or more ground plates 402, one or more mounting brackets 404, one or more seals 408, and one or more antennas 406. Antennas 406 may include one or more satellite antennas 202 and / or one or more LTE antennas 204 ( FIGS. 2A and 2B ). Other antennas are also contemplated. In some examples, piece parts 502 further include one or more wiring harnesses 410 and one or more datum blocks 412. An assembled first vehicle roof subassembly 504 is shown in FIG. 5 , and its assembly aspects are further described below with reference to that figure.

[0045] Referring to FIG. 4B, exemplary components of a second vehicle roof subassembly or kit of parts are shown. These exemplary components include a wrapped polymer substrate 114 and one or more insulating layers 108 (each visible in FIG. 1). These components may be bonded together by an adhesive to form an inner substrate assembly 106 (also visible in FIG. 1 and shown in assembled form as second vehicle roof subassembly 506 in FIG. 5). Second vehicle roof subassembly 506 may be comprised of, or may at least include, inner substrate assembly 106 of FIG. 6.

[0046] In the configuration and / or form of the vehicle roof assembly, some examples include materials for the inner substrate assembly 106 to optimize thermal insulation and noise attenuation. Some materials may be selected for their thermal and sound absorbing properties and suitability for incorporation into a vehicle roof assembly.

[0047] Polyurethane foam has excellent thermal insulation and sound absorption properties. Its versatility allows it to be molded to the complex geometric shapes of vehicle roofs, resulting in a custom fit that enhances its thermal insulation and noise attenuation performance. Another suitable material is polyethylene foam, which is lightweight and has good thermal insulation properties. Polyethylene foam also contributes to sound deadening and can be effectively used in vehicle roof assemblies where weight reduction is a priority. Melamine foam can be utilized within vehicle roof assemblies due to its excellent sound absorption properties. While primarily known for its sound absorption properties, melamine foam also provides excellent thermal insulation, making it a dual-purpose material in the automotive field. Mass-loaded vinyl (MLV) is a relatively dense material that can function as an effective barrier against airborne noise. When incorporated into vehicle roof assemblies, MLV can significantly reduce the transmission of external noise into the cabin, enhancing the overall acoustic comfort of occupants. Closed-cell foam is another material that offers excellent thermal insulation and is moisture-resistant. This moisture resistance is particularly beneficial for preventing condensation within the vehicle roof assembly, thereby maintaining the efficiency of the insulation over time.

[0048] In some instances of the inner substrate assembly 106 that address both thermal and acoustic challenges, thermal-acoustic insulating panels can be used. These panels typically include an acoustic layer bonded to an insulating layer, often made from materials such as polypropylene or polyester fiber. In applications where space is at a premium, aerogel insulation can be used due to its excellent insulating properties in very thin profiles. While aerogel is a more expensive option, its performance can justify the cost in certain design scenarios.

[0049] Fabric-based insulation materials made from nonwoven fabrics offer a lightweight, versatile option for both thermal and acoustic insulation. These fabrics can be treated with flame retardants to ensure compliance with automotive safety standards, making them a safe option for vehicle roof assemblies. Finally, viscoelastic damping compounds can be applied to substrates within vehicle roof assemblies to reduce vibration and noise transmission. These compounds are particularly effective at damping resonant frequencies that contribute to in-cabin noise. When selecting materials for the interior substrate assembly, exemplary factors may include weight, flammability, ease of installation, environmental resistance, and compliance with automotive safety standards. In some instances, a combination of the aforementioned materials is used to achieve an optimal balance of thermal insulation, noise reduction, and overall vehicle performance.

[0050] 4C shows an exemplary first adhesive application pattern 414 for bonding the wrapped polymer substrate 114 and the insulating layer 108 together to form the inner substrate assembly 106 of the second vehicle roof subassembly 506. Other adhesive patterns are also contemplated.

[0051] Some examples disclosed herein include methods. Next, with reference to FIG. 5 , exemplary steps in a method for forming a vehicle roof will be described. While the described flow may show steps as a series of processes, many of the steps may be performed in parallel or simultaneously. Furthermore, the order of the steps may be rearranged. A process ends when that step is completed. A process may correspond to a method, a procedure, an algorithm, or the like. The operations of a method may be performed in whole or in part, may be performed in conjunction with some or all of the operations of other methods, and may be performed by any number of different systems, such as the systems described herein, or any portion of a system, such as a processor included in any of the systems.

[0052] In step 508, the outer RF transparent polymer roof panel 104 and the piece components 502 are mechanically assembled or bonded together to form the assembled first vehicle roof subassembly 504. In step 510, one or more adhesive-receiving surfaces of the second vehicle roof subassembly 506 are pre-treated (surface pre-treatment), and adhesive is applied thereto. The second vehicle roof subassembly 506 may be pre-assembled as described above with reference to FIG. 4B . In step 512, the first vehicle roof subassembly 504 and the second vehicle roof subassembly 506 are positioned or otherwise aligned together (component positioning) and bonded together to form the completed outer and inner subassemblies 514. The foregoing steps may be completed as part of a typical vehicle assembly performed, for example, by the vehicle manufacturer or by a supplier of the completed outer and inner subassemblies 514. The following steps may be completed as part of a typical vehicle assembly performed by the vehicle manufacturer.

[0053] To facilitate assembly, in step 516, the completed outer and inner subassemblies 514 may be inverted, for example, on a vehicle assembly line at a vehicle manufacturing plant. In step 518, the antenna module and mounting housing 222 and closure panel 602 are mechanically assembled to the completed outer and inner subassemblies 514. The completed outer and inner subassemblies 514 may or may not be inverted when the antenna module and mounting housing 222 and closure panel 602 are mechanically assembled to the completed outer and inner subassemblies 514 to form the completed vehicle roof assembly 102. In step 520, one or more adhesive-receiving surfaces of the completed vehicle roof assembly 102 are pretreated (surface pretreatment), and adhesive is applied thereto. The adhesive may be applied, for example, in the second adhesive application pattern 604 shown in FIG. 6 . In step 522, the vehicle roof assembly 102 is bonded to the vehicle. The vehicle roof assembly 102 may be bonded to the vehicle in a position and configuration such as that shown in FIG. 1 . Other locations, configurations, and various vehicle roof types are possible.

[0054] Thus, in some examples, vehicle roof assemblies are designed to incorporate one or more antennas directly into the exterior RF-transparent polymer roof panel. This integration can help maintain the vehicle's sleek design by eliminating the need for traditional external antennas that can disrupt the vehicle's aerodynamic profile and aesthetic appeal. The antennas are strategically embedded within or adjacent to a polymer material selected for its RF transparency, eliminating metal obstructions that may interfere with signal transmission or reception.

[0055] In particular, the integrated antenna is configured to meet stringent field of view (FOV) requirements that may be important, or at least useful, for robust communications. For LTE communications, in some examples, the antenna provides an FOV ranging from 0 to 30 degrees above the horizon, ensuring reliable connectivity with cellular networks. For GNSS communications, in some examples, an FOV of 75 degrees above the zenith allows for accurate satellite navigation without signal obstructions.

[0056] The antenna module and mounting housing, which houses the integrated antenna, acts as a hub for various vehicle functions. It integrates multiple components, including those required for satellite communications, LTE communications, the internal infotainment system such as microphones and switches, and external RF communications. This integration results in a reduction of endpoints and electrical connections within the vehicle, streamlining the assembly process and improving overall system performance.

[0057] Furthermore, in some instances, the integrated antenna is designed to withstand adverse weather conditions that may be a consideration for vehicle operation. An example is to ensure that antenna performance is not impaired by ice or snow accumulation on the exterior of the vehicle. This can be achieved in some instances without the need for additional structural elements, such as heater grids or wipe zones, that may be necessary to maintain antenna functionality in such conditions.

[0058] In FIG. 6, an enlarged view of the completed vehicle roof assembly 102 is provided showing the first vehicle roof subassembly 504, the antenna module and mounting housing 222, the closure panel 602, and an exemplary second adhesive application pattern 604.

[0059] FIG. 7 shows a table 702 of example specifications for various components of the vehicle roof assembly 102 .

[0060] Referring now to FIG. 8 , exemplary steps in a method 800 for assembling a vehicle roof will be described. While the described flow may show steps as a series of processes, many of the steps may be performed in parallel or simultaneously. Additionally, the order of operations may be rearranged. A process terminates upon completion of its operations. A process may correspond to a method, a procedure, an algorithm, or the like. Method operations may be performed in whole or in part, in conjunction with some or all of the operations of other methods, or by any number of different systems, such as those described herein, or any portion of a system, such as a processor included in any of the systems.

[0061] In step 802, the method 800 provides an outer RF-transparent polymer roof panel. In step 804, the method 800 attaches a plurality of mounting brackets to the outer RF-transparent polymer roof panel. In step 806, the method 800 aligns the outer RF-transparent polymer roof panel using a datum block. In step 808, the method 800 secures an inner substrate assembly with an integral insulator to the outer RF-transparent polymer roof panel.

[0062] In some examples, method 800 may further include incorporating one or more antennas within the outer RF transparent polymer roof panel for RF communications. In some examples, method 800 may further include pre-loading the outer RF transparent polymer roof panel with one or more electrical components and configuring the outer RF transparent polymer roof panel to be installed as a single unit in a vehicle roof subassembly.

[0063] In some examples, the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

[0064] In some examples, the method 800 further includes wrapping a polymer substrate of the inner substrate assembly and bonding an insulating layer to the wrapped polymer substrate to enhance the thermal and acoustic insulation properties of the vehicle roof assembly.

[0065] In some examples, method 800 further includes selecting a material for the outer RF-transparent polymer roof panel from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA). Method 800 may further include applying an adhesive between the outer RF-transparent polymer roof panel and the inner substrate assembly to allow for deflection during impact. Method 800 may further include molding one or more rib features into the RF-transparent polymer roof without an additional metal roof crossbow.

[0066] In some examples, method 800 may further include testing the assembled RF-transparent vehicle roof to meet head impact safety standards. In some examples, the exterior RF-transparent polymer roof panel is treated to be opaque to reduce solar radiation transmission to the vehicle interior. Method 800 may further include configuring the exterior RF-transparent polymer roof panel and the interior substrate assembly to stroke together through flexure. Other technical features may be readily apparent to those skilled in the art from the following drawings, description, and claims.

[0067] In some instances, integration of the vehicle roof assembly with other vehicle systems is facilitated by the RF transparency of the polymer roof panels, which may enable seamless communication between the vehicle's internal electronic modules and external devices, such as satellite and cellular networks, without the need for external antennas that can disrupt the vehicle's aerodynamic profile and aesthetic design.

[0068] In some instances, manufacturing processes for vehicle roof assemblies include techniques such as ultrasonic welding or heat staking that provide robust and reliable bonds between polymer components without compromising RF transparency. These processes are optimized for efficiency, reducing cycle times and costs while maintaining high quality standards.

[0069] In some instances, the materials selected for a vehicle roof assembly are selected not only for their functional properties but also for their environmental impact: the polymers used are recyclable and have been evaluated for their life cycle impact, ensuring that the vehicle roof assembly is as sustainable as it is functional.

[0070] example

[0071] Thus, some embodiments may include one or more of the following examples.

[0072] Example 1 A vehicle roof assembly comprising an outer RF transparent polymer roof panel and an inner substrate assembly including an insulating layer embedded therein.

[0073] Example 2 The vehicle roof assembly of Example 1, wherein the exterior RF transparent polymeric roof panel is constructed from a material selected from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA).

[0074] Example 3. The vehicle roof assembly of Example 1 or Example 2, further comprising one or more antennas integrated within the outer RF transparent polymer roof panel for communicating with an external device.

[0075] Example 4 The vehicle roof assembly of any one of Examples 1 to 3, wherein the outer RF transparent polymer roof panel is pre-mounted with one or more electrical components and configured to be installed within the vehicle roof subassembly as a single unit.

[0076] Example 5. The vehicle roof assembly of Example 4, wherein the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user-operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

[0077] Example 6. The vehicle roof assembly of any one of Examples 1 to 5, wherein the inner substrate assembly comprises a wrapped polymer substrate and an insulating layer bonded to the wrapped polymer substrate to enhance the thermal and acoustic insulation properties of the vehicle roof assembly.

[0078] Example 7 The vehicle roof assembly of any one of Examples 1 to 6, wherein the exterior RF transparent polymer roof panel is opaque to reduce solar radiation transmission to the interior of the vehicle.

[0079] Example 8 The vehicle roof assembly of any one of Examples 1 to 7, wherein the outer RF transparent polymer roof panel and the inner substrate assembly are joined using an adhesive that allows for deflection of the vehicle roof assembly during impact.

[0080] Example 9. The vehicle roof assembly of any one of Examples 1 to 8, wherein the exterior RF transparent polymeric roof panel includes one or more molded rib features and is free of additional metal roof crossbows.

[0081] Example 10 The vehicle roof assembly of any one of Examples 1 to 9, wherein the outer RF transparent polymer roof panel is dent and corrosion resistant.

[0082] Example 11. The vehicle roof assembly of any one of Examples 1 to 10, wherein the outer RF transparent polymer roof panel and the inner substrate assembly are configured to stroke together upon flexure.

[0083] Example 12. A method for assembling a vehicle roof, comprising the steps of: providing an outer RF transparent polymer roof panel; attaching a plurality of mounting brackets to the outer RF transparent polymer roof panel; aligning the outer RF transparent polymer roof panel using a datum block; and fastening an inner substrate assembly with an integral insulator to the outer RF transparent polymer roof panel.

[0084] Example 13. The method of Example 12, further comprising incorporating one or more antennas into the exterior RF transparent polymer roof panel for RF communication.

[0085] Example 14. The method of Examples 12 or 13, further comprising pre-attaching one or more electrical components to the outer RF transparent polymeric roof panel and configuring the outer RF transparent polymeric roof panel to be installed as a single unit in a vehicle roof subassembly.

[0086] Example 15. The method of Example 14, wherein the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user-operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

[0087] Example 16. The method of any one of Examples 12 to 15, further comprising wrapping a polymer substrate of the inner substrate assembly and bonding an insulating layer to the wrapped polymer substrate to enhance thermal and acoustic insulation properties of the vehicle roof assembly.

[0088] Example 17. The method of any one of Examples 12 to 16, further comprising the step of selecting a material for the exterior RF transparent polymeric roof panel from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA).

[0089] Example 18. The method of any one of Examples 12 to 17, further comprising applying an adhesive between the outer RF transparent polymer roof panel and the inner substrate assembly to allow for deflection during impact.

[0090] Example 19. The method of any one of Examples 12 to 18, further comprising molding one or more rib features into the RF transparent polymer roof without the additional metal roof crossbow.

[0091] Example 20. The method of any one of Examples 12 to 19, further comprising testing the assembled RF transparent vehicle roof to comply with head impact safety standards.

[0092] Example 21 The method of any one of Examples 12 to 20, wherein the exterior RF transparent polymer roof panel is treated to be opaque to reduce solar radiation transmission to the interior of the vehicle.

[0093] Example 22 The method of any one of Examples 12 to 21, further comprising configuring the outer RF transparent polymer roof panel and the inner substrate assembly to stroke together upon flexure.

[0094] Example 23. A vehicle roof assembly kit comprising an outer RF transparent polymer roof panel, a plurality of mounting brackets, one or more datum blocks for alignment during assembly, and an inner substrate assembly with an integral insulator.

[0095] Example 24 The vehicle roof assembly kit of Example 23, wherein the exterior RF transparent polymeric roof panel is comprised of a material selected from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA).

[0096] Example 25. The vehicle roof assembly kit of Examples 23 or 24, further comprising one or more antennas for incorporation within the outer RF transparent polymer roof panel for communicating with an external device.

[0097] Example 26. The vehicle roof assembly kit of any one of Examples 23 to 25, wherein the exterior RF transparent polymer roof panel is pre-mounted with one or more electrical components and configured to be installed within the vehicle roof subassembly as a single unit.

[0098] Example 27. The vehicle roof assembly kit of Example 26, wherein the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user-operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

[0099] Example 28. A vehicle roof assembly comprising an exterior RF transparent polymer roof panel and one or more antennas integrated within the exterior RF transparent polymer roof panel, the one or more antennas configured to communicate with an external device without a metal occlusion.

[0100] Example 29. The vehicle roof assembly of Example 28, wherein the one or more antennas are configured to meet specific field of view (FOV) requirements, including a range of 0 degrees to 30 degrees from the horizon for LTE communications and a range of 75 degrees from the zenith for GNSS communications.

[0101] Example 30. The vehicle roof assembly of Example 28 or 29, wherein the one or more antennas are part of an electronic module that integrates functionality selected from the group including satellite communications, LTE communications, interior infotainment, and exterior RF communications.

[0102] Example 31. The vehicle roof assembly of any one of Examples 28 to 30, wherein the one or more antennas are designed to maintain performance under adverse weather conditions, including the presence of ice or snow, the absence of a heater grid or wipe zone.

[0103] In some examples, a method of manufacturing a vehicle roof assembly includes selecting an RF transparent polymer material for an outer roof panel, utilizing a joining technique selected from the group consisting of ultrasonic welding, heat staking, and adhesive bonding to bond the outer roof panel to an inner substrate assembly, and incorporating an electronic module within the outer roof panel using a process that maintains the RF transparency of the assembly.

[0104] In some examples, the materials selected for the outer RF transparent polymer roof panel and inner substrate assembly are recyclable and are selected based on a life cycle assessment to minimize environmental impact.

[0105] In some examples, an acoustic layer is incorporated into the inner substrate assembly 106 and is constructed from a material selected from the group consisting of melamine foam, polyurethane foam, and fibrous insulation material to enhance the sound-deadening properties of the assembly.

[0106] In some examples, the insulating layer incorporated within the inner substrate assembly comprises an aerogel material, which provides thermal insulating properties while minimizing the thickness of the layer.

[0107] In some examples, a vehicle roof assembly kit includes an outer RF-transparent polymer roof panel with an electronic module pre-mounted thereon, an inner substrate assembly including an integral insulating layer, and a set of modular components configured for rapid assembly onto a vehicle frame, the modular components including at least one of a datum block, a mounting bracket, and a sealing element.

[0108] It should be noted that the above description and figures, together with the examples described herein, merely illustrate the principles of the present subject matter and should not be construed as limiting the present subject matter. It is therefore understood that various configurations can be devised that embody the principles of the present subject matter, although not explicitly described or shown herein. Furthermore, all statements herein reciting principles, aspects, and implementations of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0109] It is to be understood that not necessarily all objectives or advantages may be achieved in accordance with any particular example described herein. Thus, for example, those skilled in the art may recognize that some examples may be operated to achieve or optimize one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.

[0110] All of the processes described herein may be embodied and fully automated via software code modules executed by a computing system including a computer or processor. The code modules may be stored on any type of non-transitory computer-readable medium or other computer storage device. Some or all of the methods may be embodied in dedicated computer hardware.

[0111] Many other variations beyond those described herein will be apparent from this disclosure. For example, depending on the example, some operations, events, or functions of any of the algorithms described herein may be performed in a different order, or may be added, combined, or entirely eliminated (e.g., not all described operations or events may be required to implement an algorithm). Furthermore, in some examples, operations or events may be performed simultaneously rather than sequentially, for example, via multithreading, interrupt processing, or multiple processors or processor cores, or other parallel architectures. Furthermore, different tasks or processes may be performed by different machines and / or computing systems that can function together.

[0112] The various illustrative logical blocks and modules described in connection with the examples disclosed herein may be implemented or performed by a machine, such as a processing unit or processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, designed to perform the functions described herein. A processor may be a microprocessor, but in alternative examples, a processor may be a controller, microcontroller, or state machine, combinations thereof, etc. A processor may include electrical circuitry for processing computer-executable instructions. In some examples, a processor includes an FPGA or other programmable device that performs logical operations without processing computer-executable instructions. A processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, a microprocessor in combination with a DSP core, or any other such configuration.

[0113] Although described herein primarily in terms of digital technology, a processor may also include primarily analog components. A computing environment may include any type of computer system, including, but not limited to, a computer system based on a microprocessor, a mainframe computer, a digital signal processor, a portable computing device, a device controller, or a computational engine within an appliance, to name a few. Elements of a method, process, routine, or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor device, or a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, a hard disk, a removable disk, a CD-ROM, or any other form of non-transitory computer-readable storage medium. A typical storage medium may be coupled to a processor device such that the processor device can read information from, and write information to, the storage medium. Alternatively, the storage medium may be integral to the processor device. The processor device and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. Alternatively, the processor device and the storage medium may reside as discrete components within a user terminal.

[0114] The processes described herein or illustrated in the figures of this disclosure may be initiated in response to an event, such as a predetermined or dynamically determined schedule, on demand when initiated by a user or system administrator, or in response to some other event. When such processes are initiated, a set of executable program instructions stored on one or more non-transitory computer-readable media (e.g., hard drives, flash memory, removable media, etc.) may be loaded into memory (e.g., RAM) of a server or other computing device. The executable instructions may then be executed by a hardware-based computer processor of the computing device. In some embodiments, such processes, or portions thereof, may be implemented in multiple computing devices and / or multiple processors, either serially or in parallel.

[0115] While the flow diagrams described herein may depict operations as a sequential process, many of the operations may be performed in parallel or simultaneously. Further, the order of operations may be rearranged. A process terminates when its operations are completed. A process may correspond to a method, a procedure, an algorithm, etc. The operations of a method may be performed in whole or in part, may be performed in conjunction with some or all of the operations of other methods, and may be performed by any number of different systems, such as the systems described herein, or any part of a system, such as a processor included in any of the systems.

[0116] In particular, conditional language such as "can," "could," "might," or "may" is understood within the context in which it is generally used to convey that some examples include certain features, elements, and / or steps, while other examples do not, unless otherwise specified. Thus, such conditional language is generally not intended to imply that the features, elements, and / or steps are somehow exemplary of the examples, or that the examples necessarily include logic for determining whether those features, elements, and / or steps are included in or should be performed in any particular example, with or without user input or prompting.

[0117] Disjunctive language such as the phrase "at least one of X, Y, or Z" is generally understood in the context of usage to indicate that an item, term, etc. can be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z), unless specifically stated otherwise. Thus, such disjunctive language generally does not and should not imply that at least one of X, at least one of Y, or at least one of Z is required for some instance to exist, respectively.

[0118] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or depicted in the accompanying figures should be understood as potentially representing modules, segments, or portions of code containing executable instructions for implementing specific logical functions or elements in the process. As will be appreciated by those skilled in the art, alternative examples are included within the scope of the examples described herein in which elements or functions may be omitted or performed in a different order than that shown or described, including substantially simultaneously or in reverse order, depending on the functionality involved.

[0119] It should be emphasized that many variations and modifications can be made to the foregoing examples, and that the elements thereof are to be understood as being among other acceptable examples, and all such modifications and variations are intended to be included within the scope of this disclosure.

[0120] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or depicted in the accompanying figures should be understood as potentially representing modules, segments, or portions of code containing executable instructions for implementing specific logical functions or elements in the process. As will be appreciated by those skilled in the art, alternative examples are included within the scope of the examples described herein in which elements or functions may be omitted or performed in a different order than that shown or described, including substantially simultaneously or in reverse order, depending on the functionality involved.

[0121] Unless otherwise specified, articles such as "a" or "an" should generally be construed to include one or more listed items. Thus, phrases such as "a device configured to" are intended to include one or more of the listed devices. Also, such one or more listed devices may be collectively configured to perform the stated enumeration. For example, "a processor configured to perform enumerations A, B, and C" may include a first processor configured to perform enumeration A working in conjunction with a second processor configured to perform enumerations B and C.

[0122] It is also understood that one or more of the elements depicted in the drawings / diagrams may be implemented in a more separated or integrated manner as may be useful according to a particular application, or may even be removed or rendered inoperable in certain cases.

Claims

1. an exterior RF transparent polymer roof panel; an inner substrate assembly having an insulating layer embedded therein; A vehicle roof assembly comprising:

2. 10. The vehicle roof assembly of claim 1, wherein the outer RF transparent polymeric roof panel is constructed from a material selected from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA).

3. The vehicle roof assembly of claim 1 further comprising one or more antennas integrated within said outer RF transparent polymer roof panel for communicating with external devices.

4. 10. The vehicle roof assembly of claim 1, wherein the outer RF transparent polymeric roof panel is pre-mounted with one or more electrical components and is configured to be installed as a single unit within a vehicle roof subassembly.

5. 5. The vehicle roof assembly of claim 4, wherein the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

6. 10. The vehicle roof assembly of claim 1, wherein the inner substrate assembly comprises a wrapped polymer substrate and an insulating layer bonded to the wrapped polymer substrate to enhance thermal and acoustic insulation properties of the vehicle roof assembly.

7. 10. The vehicle roof assembly of claim 1, wherein the outer RF transparent polymer roof panel is opaque to reduce solar radiation transmission into the vehicle interior.

8. 10. The vehicle roof assembly of claim 1, wherein the outer RF transparent polymer roof panel and the inner substrate assembly are joined using an adhesive that allows for deflection of the vehicle roof assembly during an impact.

9. The vehicle roof assembly of claim 1 , wherein the outer RF transparent polymeric roof panel includes one or more molded rib features and is free of additional metal roof crossbows.

10. 10. The vehicle roof assembly of claim 1, wherein said outer RF transparent polymeric roof panel is dent and corrosion resistant.

11. The vehicle roof assembly of claim 1 , wherein the outer RF transparent polymer roof panel and the inner substrate assembly are configured to stroke together upon flexure.

12. 1. A method for assembling a vehicle roof, comprising: providing an exterior RF transparent polymer roof panel; attaching a plurality of mounting brackets to the exterior RF transparent polymeric roof panel; aligning the outer RF transparent polymer roof panel using a datum block; securing an inner substrate assembly with an integral insulator to the outer RF transparent polymer roof panel; A method comprising:

13. The method of claim 12 further comprising incorporating one or more antennas into the exterior RF transparent polymer roof panel for RF communications.

14. 13. The method of claim 12, further comprising the steps of pre-equipping the outer RF transparent polymeric roof panel with one or more electrical components and configuring the outer RF transparent polymeric roof panel to be installed as a single unit in a vehicle roof subassembly.

15. 15. The method of claim 14, wherein the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

16. 13. The method of claim 12, further comprising wrapping a polymer substrate of the inner substrate assembly and bonding an insulating layer to the wrapped polymer substrate to enhance thermal and acoustic insulation properties of the vehicle roof assembly.

17. 13. The method of claim 12, further comprising the step of selecting a material for the outer RF transparent polymeric roof panel from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA).

18. The method of claim 12 further comprising applying an adhesive between the outer RF transparent polymer roof panel and the inner substrate assembly to allow for deflection during impact.

19. The method of claim 12 further comprising molding one or more rib features into an RF transparent polymer roof without an additional metal roof crossbow.

20. 13. The method of claim 12, further comprising testing the assembled RF transparent vehicle roof to meet head impact safety standards.

21. 13. The method of claim 12, wherein the exterior RF transparent polymer roof panel is treated to be opaque to reduce solar radiation transmission into the interior of the vehicle.

22. The method of claim 12 further comprising configuring the outer RF transparent polymer roof panel and the inner substrate assembly to stroke together through flexure.

23. an exterior RF transparent polymer roof panel; a plurality of mounting brackets; one or more datum blocks for alignment during assembly; an inner substrate assembly with an integral insulator; A vehicle roof assembly kit comprising:

24. 24. The vehicle roof assembly kit of claim 23, wherein the outer RF transparent polymeric roof panel is constructed from a material selected from a group of materials including polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and acrylonitrile styrene acrylate (ASA).

25. 24. The vehicle roof assembly kit of claim 23, further comprising one or more antennas for incorporation within said outer RF transparent polymer roof panel for communicating with external devices.

26. 24. The vehicle roof assembly kit of claim 23, wherein the outer RF transparent polymeric roof panel is pre-mounted with one or more electrical components and is configured to be installed as a single unit within a vehicle roof subassembly.

27. 27. The vehicle roof assembly kit of claim 26, wherein the one or more electrical components include an electrical component selected from the group including a map light, a microphone, a user operable switch, a satellite communication component, a speaker, a Bluetooth low energy component, and a processor.

28. A vehicle roof assembly comprising an exterior RF transparent polymer roof panel and one or more antennas integrated within the exterior RF transparent polymer roof panel, the one or more antennas configured to communicate with an external device without a metal obstruction.

29. 30. The vehicle roof assembly of claim 28, wherein the one or more antennas are configured to meet specific field of view (FOV) requirements including a range of 0 to 30 degrees from the horizon for LTE communications and a range of 75 degrees from the zenith for GNSS communications.

30. 30. The vehicle roof assembly of claim 28, wherein the one or more antennas are part of an electronics module that integrates functionality selected from the group including satellite communications, LTE communications, interior infotainment, and exterior RF communications.

31. 30. The vehicle roof assembly of claim 28, wherein the one or more antennas are designed to maintain performance under adverse weather conditions, including the presence of ice or snow, and the absence of heater grids or wipe zones.

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