Vehicle Roof Frame With Reinforced Plastic Guide Rail
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Solution Overview
Problem
Existing frame arrangements for vehicle roofs, particularly those with movable covers or roller blind devices, are not sustainable and cost-effective due to the use of metal guide rails that require additional fasteners and reworking, leading to increased weight, complexity, and potential noise issues.
Innovation Solution
A frame arrangement using a plastic guide rail stabilized by a reinforcing portion, integrated with a carriage and drive cable, eliminates the need for metal components and fasteners, reducing weight and complexity while enhancing stability and sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal guide rails are used for the frame arrangement, then the structural strength and stability are improved, but the weight increases and sustainability deteriorates
Solution Approach 1:
The patent employs composite construction by integrating a plastic guide rail with a metal reinforcing portion. The plastic component (polyamide or polyurethane) provides corrosion resistance and reduced weight, while the metal reinforcing portion (aluminum or steel profile) embedded within the plastic maintains structural strength and stability. This composite approach resolves the contradiction by combining materials with complementary properties.
2Stability of the object's composition
If metal guide rails with fasteners are used, then the structural stability is improved, but the device complexity and assembly steps increase
Solution Approach 1:
The patent merges the guide rail function and the reinforcing structure into a single integrated component. The metal reinforcing portion is embedded directly within the plastic guide rail during manufacturing, eliminating the need for separate fasteners and assembly steps. The receiving channels for the carriage are molded directly into the plastic guide rail, further simplifying the structure. This integration resolves the contradiction by reducing component count while maintaining stability.
3Strength
If metal guide rails are used, then the rigidity is improved, but the production costs and CO2 emissions increase
Solution Approach 1:
The patent changes the material parameters by transitioning from entirely metal construction to a plastic-based composite. The plastic guide rail with embedded metal reinforcing portion achieves the required rigidity through optimized geometry and material combination, while being more cost-effective and environmentally friendly. The receiving channels are molded directly into the plastic, eliminating secondary manufacturing operations required for metal components.
4Weight of moving object
If plastic guide rail is used without reinforcement, then the weight is reduced and sustainability is improved, but the structural stability deteriorates
Solution Approach 1:
The patent applies composite material construction by embedding a metal reinforcing portion within the plastic guide rail. The plastic matrix (polyamide or polyurethane) provides lightweight and corrosion-resistant properties, while the embedded metal profile (aluminum or steel) provides the necessary structural stability and rigidity. This composite approach resolves the contradiction by combining materials that complement each other's strengths.
Data Source
AI summary
A frame arrangement for a vehicle roof for supporting a deployable and displaceable cover, having a frame element extending along a first main extension axis. The frame element has a main portion which lies in a first main extension plane which is spanned by the first main extension axis and a second main extension axis, and a first reinforcing portion, which is connected to the main portion and projects along a vertical axis from the first main extension plane. The frame arrangement may further have a first plastic guide rail having at least one receiving channel for a carriage, wherein the first plastic guide rail extends along the first main extension axis and the vertical axis, and wherein the first plastic guide rail at least partially surrounds the first reinforcing portion for stabilizing the first plastic guide rail.