Integrated Roof Panel Module with Flexible Hinge
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Solution Overview
Problem
The existing roof panel modules in motor vehicles are complex to assemble due to a large number of elements and visible separation lines, which pose both functional and aesthetic challenges.
Innovation Solution
A roof panel module design featuring a reduced number of elements and separation lines, utilizing a flexible hinge and a one-piece gasket made of polyurethane foam for easy installation, with a support element connecting the trim to the outer upper panel, and a curved free end for improved contact and folding, facilitating efficient assembly and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional roof panel module with multiple elements is used, then the insulation and aesthetic functions are achieved, but the assembly process becomes long and complicated with multiple separation lines visible in the passenger compartment
Solution Approach 1:
The patent merges multiple traditional roof elements (headliner, trim, gasket) into a single integrated roof panel module. The module comprises an outer upper panel, a headliner, and a trim formed as one piece, eliminating the need for separate assembly of multiple components and reducing visible separation lines in the passenger compartment.
Solution Approach 2:
The integrated module is designed with a flexible hinge that allows it to be folded into a compact configuration for easy installation through the vehicle opening, then deployed to its final position where it functions as a complete assembly. This segmentation in the installation process resolves the contradiction between integration benefits and installation complexity.
2Shape
If multiple trim elements are used to cover the complex body architecture, then the aesthetic function is improved, but the number of separation lines increases and assembly complexity increases
Solution Approach 1:
The trim, headliner, and gasket are merged into a single monolithic piece with integrated functionality. This single component covers the complex body architecture while maintaining aesthetic appearance, eliminating the need for multiple separate trim elements and their associated separation lines.
Solution Approach 2:
The flexible hinge introduces dynamic capability to the otherwise rigid trim structure, allowing it to adapt to the complex body architecture during installation and then maintain a stable, aesthetically pleasing final configuration. The hinge enables the trim to fold and deploy while maintaining its integrated form.
3Strength
If a rigid gasket structure is used, then the structural strength is improved, but the ease of installation and folding is reduced
Solution Approach 1:
The gasket is designed with a flexible hinge that transforms it from a rigid structure to a dynamic, foldable component. The hinge allows the gasket to be folded during installation for easy access through the vehicle opening, then deployed to its final position where it provides the necessary structural strength and sealing function.
Solution Approach 2:
The gasket material and structure are designed to change their physical parameters - flexible during installation for easy folding, then rigid in the final configuration to provide structural strength and effective sealing. This parameter change resolves the contradiction between strength and ease of installation.
Data Source
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AI summary
The invention relates to a motor vehicle comprising a roof panel module (4) located at the top of the body (1) of the vehicle, the top of the body of the vehicle (1) including an outer side panel (2) and an inner side panel (3), the bottom portions of the inner and outer side panels (2, 3) being connected and forming a recess (19), the roof panel module (4) including an outer top panel (7), a support member (9) and a roof liner (8), the liner (8) including a central portion (8a) and a peripheral portion (8b) having a free end (13) which oriented downward. Furthermore, the two portions (8a, 8b) are connected to one another by a flexible hinge (10), the peripheral portion (8b), the central portion (8a) and the hinge (10) are integrally formed, and the free end (13) of the peripheral portion of the liner (8b) is oriented downward and secured in the recess (19).