Sunroof Motor Relocation and Linkage Design
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Solution Overview
Problem
Existing sunroof designs in passenger vehicles compromise on 'hands through' and 'day light' opening sizes due to the placement of kinematic systems at the roof line, which reduces interior volume and increases noise levels, while also limiting torque capability and increasing size and soundproofing requirements.
Innovation Solution
A moveable panel system with a pair of tracks along the roof's lateral edges and independent mechanical linkages coupled to motors mounted below the roof line, allowing for larger openings and reduced noise by positioning the guide tracks outside the primary sealing system, thus enhancing headroom and reducing noise for passengers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the kinematic system is placed at the roof line, then the sunroof can be controlled to open and close, but the interior volume is reduced and noise level increases
Solution Approach 1:
The motor assembly is extracted from the roof line location and relocated to the lower body structure of the vehicle. This extraction removes the noise and volume-consuming components from the passenger compartment vicinity while maintaining the sunroof control function through extended linkages and cables that reach from the lower motor location to the roofline sunroof mechanism.
Solution Approach 2:
Extended linkages and cables serve as intermediaries to transmit the mechanical force and motion from the lower-mounted motor assembly to the sunroof mechanism at the roof line. These intermediaries enable the motor to be positioned away from the roof while still controlling the sunroof panel.
2Ease of operation
If the kinematic system is placed at the roof line, then the sunroof can be controlled, but the noise level for operator and passengers increases
Solution Approach 1:
The motor assembly generating noise is extracted from the roof line location where it would directly expose passengers to noise, and relocated to the lower body structure where noise is less intrusive and can be better isolated from the passenger compartment.
3Object-generated harmful factors
If additional soundproofing is added to reduce noise, then noise level decreases, but the volume of the passenger compartment is further reduced
Solution Approach 1:
By extracting the noise-generating motor from the roof line area, the patent eliminates the need for extensive soundproofing materials in the passenger compartment, thereby preserving interior volume while still achieving noise reduction goals.
4Strength
If the motor torque capability is increased, then the sunroof can handle larger panels, but the motor size increases
Solution Approach 1:
Mechanical linkages and cables act as force transmission intermediaries that can multiply and transmit motor force over long distances. This allows a smaller motor located in the lower body to generate sufficient torque at the roofline sunroof mechanism through the mechanical advantage provided by the linkage system.
5Reliability
If the guide tracks are placed inside the primary sealing system, then environmental sealing is maintained, but the hands through opening size is limited
Solution Approach 1:
The patent uses intermediate sealing mechanisms and extended track configurations that allow the guide tracks to extend beyond the primary sealing system boundaries. This enables larger panel travel and opening sizes while maintaining environmental sealing through additional sealing elements positioned at the extended track locations.
Data Source
AI summary
Continuous cross sectional profile guide tracks in an outer sliding sunroof/moonroof are provided where both the front and rear mechanism or mechanism links travel fore/aft in the same channels as each other and have fore/aft travel that is limited only by vehicle architecture. The guide track channel is partly or entirely outside/outboard of the primary water/wind sealing system of the sunroof.