Thermoformed Roof Module Channel for Air and Light Distribution
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Solution Overview
Problem
Existing roof modules for motor vehicles lack efficient integration of additional functions like ventilation and lighting while being easy and cost-effective to manufacture.
Innovation Solution
A roof module comprising a thermoformed plastic roof liner and side parts connected via a sealing component, forming a channel open to the vehicle interior for air or light distribution, utilizing a U-profile connecting component and clips for assembly, and an air hose for ventilation without additional nozzles or covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional functions like ventilation and lighting are integrated into the roof module, then functionality is improved, but device complexity increases
Solution Approach 1:
The roof module is designed to perform multiple functions including ventilation, lighting, and acoustic insulation through integrated components. The housing contains both ventilation ducts for air flow and light guides for illumination, allowing a single roof assembly to deliver diverse functions without requiring separate systems.
Solution Approach 2:
The patent combines ventilation ducts, light guides, and acoustic insulation layers into a single integrated roof module assembly. The housing structure merges these functional elements into one unified component that can be installed as a complete unit, reducing overall system complexity while maintaining multiple functions.
2Ease of manufacture
If a modular design with multiple components is used, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The roof module is divided into distinct functional segments including the housing, ventilation ducts, light guides, and acoustic insulation layers. Each component can be manufactured separately using appropriate processes, then assembled into the complete module, facilitating specialized production and quality control for each element.
Solution Approach 2:
The design nests multiple functional elements within the housing structure - ventilation ducts are positioned within the housing cavity, light guides are integrated into the housing walls, and acoustic insulation is placed within the housing. This nested arrangement allows compact integration of multiple components while maintaining ease of assembly.
3Productivity
If ventilation ducts and light guides are integrated into the roof module, then air and light distribution efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is designed with locally optimized features for different functions - specific wall sections contain integrated light guides for optimal light distribution, while other areas incorporate ventilation ducts with appropriate cross-sections for efficient air flow. The acoustic insulation is positioned in specific locations to maximize sound absorption where needed.
Data Source
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AI summary
A roof module for a motor vehicle, comprising a headliner (2), wherein the headliner (2) is a thermoformed plastic component, a headliner side part (1) arranged outside the headliner (2) when viewed from the vehicle interior in the installed position, wherein the headliner side part (1) is a thermoformed plastic component, wherein a contact line (12) extends between the headliner (2) and the headliner side part (1), wherein the contact line (12) is formed by a connecting component, in particular a sealing component, and/or wherein the contact line (12) is formed by direct contact between the headliner (2) and the headliner side part (1), wherein, in the installed position, a gap (15) open towards the vehicle interior extends between the headliner (2) and the headliner side part (1) on the vehicle edge side of the contact line (12), such that a channel (16) is formed between the headliner (2) and the headliner side part (1) on the vehicle edge side of the contact line (12).which, when installed, is open towards the vehicle interior.