Modular Vehicle Top Using Segmented Rails and Collapsible Cover
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Solution Overview
Problem
Existing open cabin vehicle tops, typically made of large thermoformed plastic, fiberglass, or composite materials, face challenges in shipping due to size and fragility, leading to increased costs and time delays, and are prone to deformation from heat exposure, necessitating frequent replacements.
Innovation Solution
A modular top system comprising rail sections, corner brackets, and a flexible, collapsible cover that can be easily assembled and disassembled, allowing for compact shipping and featuring deployment channels, trusses for support, and accessory connectors for customization, reducing the need for large, fragile panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large thermoformed roof panel is used to cover the passenger cabin, then protection coverage is improved, but packaging size and shipping cost increase
Solution Approach 1:
The roof panel is segmented into multiple smaller modules that can be packaged in smaller, more manageable boxes. This reduces the volume of individual shipping packages while maintaining the total protective coverage when assembled.
Solution Approach 2:
The modular sections are designed to assemble in three-dimensional space, creating a large protective surface from smaller components. The sections can be configured in various arrangements to achieve the required coverage area without requiring a single large package.
2Reliability
If a large thermoformed roof panel is used to provide comprehensive coverage, then passenger protection is improved, but susceptibility to heat deformation increases
Solution Approach 1:
Dividing the roof into smaller modular sections reduces the total surface area exposed to concentrated heat, lowering the risk of thermal deformation. Each smaller section can be independently managed regarding thermal exposure and replacement if needed.
Solution Approach 2:
The invention changes the material parameters by using UV-resistant and heat-resistant materials in the modular sections. This alters the thermal properties of the roof system, making it more resistant to heat-induced deformation while maintaining protective coverage.
3Reliability
If duplicative roof panels are shipped to ensure delivery, then delivery reliability is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the roof into multiple modular sections, the risk of complete failure during shipping is reduced. Even if some sections are damaged, others can likely be delivered and used, eliminating the need to ship complete duplicate panels.
Solution Approach 2:
The modular design allows for selective replacement of only the damaged sections rather than requiring replacement of entire panels. This reduces the quantity of material that needs to be shipped as backup, lowering manufacturing costs while maintaining delivery reliability.
Data Source
AI summary
A modular top system for a vehicle is provided. In various embodiments, the system includes a plurality of rail sections, a plurality of corner brackets for connecting the rail sections to form a frame, and a flexible, collapsible cover to be deployed over and connected to the frame. The modular top system can additionally include a plurality of cover connecting devices disposable on a periphery of each of the sides of the cover. Each connecting device is for removably connecting each respective cover side to the frame to deploy the cover over and connect the cover to the frame. Each rail section can comprise at least one assembly connector for connecting any of a plurality of system assembly components to the respective rail section, and/or at least one accessory connector for connecting at least one modular top accessory to the respective rail section.