Plastic Guide Rail Roof Mechanism With Single-Drive Cover Motion

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Solution Overview

Problem

Existing vehicle roof designs face challenges in achieving a cost-effective, space-saving construction while reducing CO2 emissions and noise generation, particularly due to the use of conventional metal guide rails that require multiple drive units and occupy significant installation space.

Innovation Solution

A vehicle roof device featuring an extendable, adjustable cover mechanism with a plastic guide rail and lever system, utilizing a single electric drive unit, which includes a plastic guide rail with integrated guide and cam tracks, allowing seamless movement and a robust locking function.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional metal guide rails are used, then the guide rail provides robust guidance and structural strength, but the device complexity increases, installation space increases, and CO2 emissions increase

Engineering Contradiction:

Improveguidance reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the conventional metal guide rail mechanical system with a plastic guide rail system that integrates multiple functions into a single component. The plastic guide rail incorporates guide channels, cam tracks, and locking mechanisms directly into its structure, eliminating the need for separate metal components and reducing overall device complexity while maintaining guidance reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges multiple functions (guidance, locking, movement control) into a single integrated plastic guide rail component. The guide rail combines guide channels for the drive carriage, cam tracks for the lever mechanism, and locking features in one piece, reducing the number of parts and simplifying the overall device structure.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If conventional metal guide rails are used, then the guide rail provides structural strength, but the installation space increases

Engineering Contradiction:

Improvestructural strengthVSAvoidinstallation space

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The patent combines multiple structural functions into the plastic guide rail, integrating guide channels, cam tracks, and locking mechanisms into a single compact component. This integration reduces the overall space required for installation compared to separate metal components that would be needed to provide the same functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the material parameter from metal to plastic, which allows for different structural configurations and integrated designs. The plastic material enables the creation of complex three-dimensional guide channels and cam tracks within a compact footprint, reducing installation space while maintaining sufficient structural strength for the application.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If conventional metal guide rails are used, then the guide rail provides durability, but CO2 emissions increase

Engineering Contradiction:

Improveservice lifeVSAvoidCO2 emissions

Core Design Contradiction:

Duration of action of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from metal to plastic, which has a lower environmental impact and reduced CO2 emissions associated with production and processing. The plastic guide rail is designed to provide sufficient durability and service life for the vehicle roof application while being more environmentally friendly.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses plastic material (which can be considered a composite or engineered material) to create the guide rail, replacing traditional metal materials. This material substitution reduces CO2 emissions associated with material production and processing while maintaining the necessary mechanical properties for the application.

Inventive Principle:

Principle #40Composite materials

4Reliability

If conventional metal guide rails are used, then the guide rail provides robust guidance, but noise generation increases

Engineering Contradiction:

Improveguidance reliabilityVSAvoidnoise generation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from metal to plastic, which inherently reduces noise generation during operation. The plastic guide rail provides smooth guidance for the drive carriage and lever mechanism with less friction and impact noise compared to metal-on-metal contact, while maintaining guidance reliability through precision-molded guide channels and cam tracks.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4663441A1Device for a vehicle roof and vehicle roof for a motor vehicle

Publication Date: 2025.12.17 WEBASTO AG

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AI summary

A device (10) for a vehicle roof (1) comprises a cover (3), a lever mechanism, and a guide rail (11) made of plastic. The lever mechanism is coupled to the cover (3) and is designed to move the cover (3) relative to the vehicle roof (1). The lever mechanism has a drive carriage (12) and a plurality of levers (14, 15, 16, 18) with guide elements (22, 24-27, 30, 33-38) which are coupled to a plurality of guide and cam tracks (21, 23, 28-30) of the guide rail (11), such that the cover (3) can be moved by means of the lever mechanism and the guide rail (11) from a closed position to a ventilation position and from the ventilation position along a longitudinal axis (L) of the vehicle roof (1) to an open position.