Vehicle Roof Module RTM Frame Polyurethane Surface
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Solution Overview
Problem
Existing roof modules for motor vehicles lack improved strength, weight reduction, and high-quality surface finishes, often requiring separate attachment parts for aesthetic enhancements which increase weight and complexity.
Innovation Solution
A roof module combining an RTM frame with a polyurethane Class-A covering layer, where the RTM frame is made using the Resin Transfer Molding method with a fiber mat, and the polyurethane is introduced in a second mold to form a high-strength, lightweight structure with a self-healing surface, optionally using a thermoplastic film for insulation and adhesion, and pre-embossing for complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional roof module is made from glass or sheet metal, then strength and rigidity are achieved, but weight is high and material adjustability is limited
Solution Approach 1:
The patent uses composite materials by combining a fiber-reinforced plastic frame (made from fiber mat and reactive resin system) with a polyurethane foam covering layer. This composite structure achieves high strength and rigidity while significantly reducing weight compared to conventional glass or sheet metal roof modules. The fiber mat provides structural strength, while the polyurethane foam provides both covering and insulation functions.
2Manufacturing precision
If separate attachment parts are mounted on the frame for aesthetic enhancement, then surface quality is improved, but weight increases and device complexity increases
Solution Approach 1:
The patent merges the aesthetic covering layer with the structural frame by directly bonding the polyurethane foam Class-A surface to the fiber-reinforced plastic frame. This integration eliminates the need for separate attachment parts that would otherwise be required for aesthetic enhancement, thereby reducing device complexity and weight while maintaining high surface quality.
Solution Approach 2:
The polyurethane foam covering layer serves multiple functions simultaneously: it provides the Class-A aesthetic surface, acts as an insulating layer, and serves as the bonding interface to the frame. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity.
3Manufacturing precision
If separate attachment parts are mounted on the frame for aesthetic enhancement, then surface quality is improved, but weight increases
Solution Approach 1:
The patent merges the aesthetic covering layer with the structural frame by directly bonding the polyurethane foam Class-A surface to the fiber-reinforced plastic frame. This integration eliminates the need for separate attachment parts that would otherwise be required for aesthetic enhancement, thereby reducing device complexity and weight while maintaining high surface quality.
4Ease of manufacture
If the fiber mat includes seams to drape different layers, then ease of manufacture is improved, but surface quality of the Class-A covering layer deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-embossing the fiber mat before placing it in the mold. This pre-shaping allows the fiber mat to be draped over complex geometries without requiring seams, thereby maintaining high surface quality on the Class-A covering layer while still enabling ease of manufacture through the pre-formed structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a strong, lightweight roof module with a high-quality, self-healing surface that reduces weight and eliminates the need for additional attachment parts, offering improved strength and aesthetic appeal without additional painting requirements.
Implementation Method 1
a reactive resin system is introduced into the closed mold and the resin cures, so that a blank is formed
Implementation Method 2
The polyurethane expands, wherein it at least partially forms a Class-A surface
Data Source
AI summary
A roof module for a motor vehicle comprises an RTM frame and a Class-A covering layer, which at least partially covers the frame and is made of polyurethane. A method for manufacturing a roof module comprises the following steps: Initially, a fiber mat is put into a first mold. Then, a reactive resin system is introduced into the closed mold and the resin cures, so that a blank is formed. The blank is put into a second mold, into which subsequently polyurethane is introduced in the open condition. The polyurethane expands, wherein it at least partially forms a Class-A surface.