Abstract:
Embodiments disclosed herein provide a vehicle roof having a roof panel formed of molded fiberglass. The panel has a first surface and a second surface. An insert is molded into the roof panel. The insert has an interior surface generally concentrically disposed about an axis that is generally perpendicular to the first surface and the second surface of the roof panel. The insert is at least substantially embedded in the roof panel.

Description:
FIELD 
       [0001]    Embodiments disclosed herein relate generally to motor vehicle assembly and more particularly to assembly of components to panels, such as roof panels, formed by resin transfer molding (RTM). 
       BACKGROUND 
       [0002]    Some vehicle roof panels call for a glass reinforced plastic shell made of one or a plurality of pieces. Vehicles are sometimes provided with a sleeper compartment, which requires the attachment of components to the roof panels. Vehicle parts that are mounted to the roof panel in sleeper compartments may include interior trim panels, HVAC ducting, cabinets, and bunks. 
         [0003]    In some constructions, after the roof panel is molded, the roof panel is then drilled to attach a backing plate to the roof panel. The backing plate is mounted to the roof panel with rivets, and once mounted, vehicle components can be attached to the backing plate. Drilling of the roof panel can result in some dimensional variation in the size of the resulting holes and in the placement of the holes in the roof panel. Such dimensional variation can result in misalignment or installation problems with the backing panel. 
       SUMMARY 
       [0004]    According to one embodiment, a vehicle roof having a roof panel formed of molded fiberglass has a first surface and a second surface. An insert is molded into the roof panel. The insert has an interior surface generally concentrically disposed about an axis that is generally perpendicular to the first surface and the second surface of the roof panel. According to another embodiment, a method of forming a fiberglass panel with an embedded insert in a mold having at least a first and a second mold component, the first mold component having a receiving portion, comprises the steps of positioning a removable locator into an interior surface of an insert. The insert has a spacer disposed around the exterior surface of the insert. The locator has a length greater than a length of the insert. A first end of the locator extends from a first side of the interior surface, and a second end of the locator extends from a second side of the interior surface. The first end of the locator is positioned into the receiving portion of the first mold component. Fiberglass is applied between the mold components. The fiberglass is cured between the mold components. The fiberglass panel and embedded insert are removed from the mold. The locator is removed from the insert. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is an elevation view of a prior art roof panel with a backing plate mounted to the roof panel. 
           [0006]      FIG. 2  is an elevation view of an insert molded into a roof panel. 
           [0007]      FIG. 3  is a section view of an insert, a spacer and a locator placed in a mold. 
           [0008]      FIG. 4  is a top view of the insert, the spacer and the locator. 
           [0009]      FIG. 5  is an elevation view of the insert disposed within the spacer, and the locator disposed within the insert. 
           [0010]      FIG. 6  is a section view of the insert, the spacer and the locator taken along line A-A of  FIG. 5 . 
           [0011]      FIG. 7  is an exploded section view of the insert and the spacer. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    Referring to  FIG. 1 , a prior roof panel  1  has a plate  2  mounted to the surface  3  of the roof panel with rivets  4 . The rivets  4  are introduced through the roof panel  1  at drilled holes  5 , which correspond in dimension and location to the holes  6  in the plate  2 . A nut  7  is welded to the plate  2  to allow the mounting of vehicle parts to the plate  2 . 
         [0013]    Referring now to  FIG. 2  and  FIG. 3 , the present roof panel is designated  10  and has an insert  12  that is molded into the roof panel. In one embodiment, the roof panel  10  is formed of fiberglass and formed in a mold generally designated  14 . While the panel  10  is a roof panel of a sleeper compartment of a vehicle, it should be appreciated that the roof panel  10  can be any component formed by resin transfer molding (RTM), including automotive components, such as roofs and hoods, as well as non-automotive components. 
         [0014]    A first portion  16  of the roof panel  10  has a thin construction compared to a second portion  18  which has a relatively thicker construction, however the thickness of the portions can vary. The insert  12  is embedded in the second portion  18  of the roof panel  10  and is generally flush with a first surface  20 , while on the opposite side of the roof panel, the insert protrudes from a second surface  22 . It is also contemplated that the insert projects from both the first surface  20  and the second surface  22 , or is generally flush at both the first surface and the second surface, or is generally flush at the second surface and projects from the first surface. 
         [0015]    The insert  12  is generally cylindrical and has a cylindrical interior surface  24  concentrically disposed around axis X of the insert  12 , which is generally perpendicular to the first surface  20  and the second surface  22 . The interior surface  24  is threaded and is configured to receive fasteners (not shown) to secure vehicle parts such as interior trim panels, HVAC ducting, cabinets, and bunks to the roof panel  10 . In the illustrated embodiment, the insert  12  is metal, however other materials may be used. 
         [0016]    Disposed generally concentrically around the insert  12  is a spacer  26 , which is metal in the illustrated embodiment, however other materials may be used. The spacer  26  has a ring  28  (see  FIG. 4 ) and a plurality of fingers  30  that project radially from the ring to space opposing mold components  32 ,  34  of the mold  14  apart from each other. In some embodiment, the ring  28  is substantially octagonal, however the ring can be circular, polygonal, or any other shape. Disposed on each side of the octagon, there is a set of fingers  30 , one of the fingers extending in a first direction generally parallel with the axis X, and one of the fingers extending in the opposite direction also generally parallel with the axis X. In this arrangement, the fingers alternate in direction around the ring  28 . It is contemplated that any number of fingers  30  can be disposed around the ring  28  in various arrangements. At the end of each finger  30  is a tapered tip  36 . 
         [0017]    Referring to  FIGS. 4-7 , the insert  12  and the spacer  26  are assembled together to form an insert assembly  38 . Alternatively, the spacer  26  and insert  12  can be unitarily formed. A shaft  40  of the insert  12  is positioned into the ring  28  of the spacer  26  (see  FIG. 6 ) until a head  42  of the insert  12  contacts the ring (see  FIG. 7 ). The insert  12  and the spacer  26  are welded together, although other methods of permanently fixing the insert and the spacer may be used. A locator  44  is axially disposed in the interior surface  24  of the insert  12  (see  FIG. 8 ) such that a first end  46  of the locator extends substantially more than a second end  48  of the locator. The length of the locator  44  is about two or three times the length of the insert  12  and is formed, in one embodiment, of nylon or any other polymer material that is able to withstand molding temperatures, however other lengths and materials can be used. Additionally, it is contemplated that the exterior surface of the locator  44  can be smooth or threaded, and further, can have indicators to indicate a desired location of the insert  12  relative to the locator. 
         [0018]    To form the roof panel  10  with embedded insert  12 , the insert assembly  38  is assembled by permanently positioning the insert  12  into the spacer  26  and the locator  44  is positioned into the insert  12 . Referring to  FIG. 3 , mold components  32  and  34  are spaced apart a distance greater than the length of the locator  44 . The mold component  32  has a receiving portion  50  being dimensioned to receive the portion of the locator  44  that extends from the first end  46  of the insert  12 . An enlarged portion  52  of the receiving portion  50  is configured to receive the first end of the insert  12 . When the locator  44  and the insert assembly  32  are placed into the mold component  32 , the locator  44  and a first end  46  of the insert are received into the receiving portion  50 , and the tips  36  of half of the fingers  30  contact a molding surface  54 . 
         [0019]    Both cold molding processes and higher temperature molding processes may be used to form the panel  10 . In one application of a cold mold process, sheets of fiberglass are placed in the open mold components  32 ,  34 , and then fiberglass resin is poured into the mold components. The mold components  32 ,  34  are closed, forcing the resin through the fiberglass fabric. Extra pieces of fiberglass fabric may be placed in areas requiring additional thickness, for example around the insert  12 . Due to the design of the fingers  30  on the insert  12 , the spacer  26  and the insert become woven into the roof panel  10 . Some of the layers of fiberglass may be applied over the top of the locator  44 . 
         [0020]    When the fiberglass layers are in place, the mold components  32  and  34  move towards each other and compress the fiberglass layers. The fingers  30  of the spacer  26  limit the distance that the mold components  32  and  34  can compress. As the components  32  and  34  compress, a pointed end  56  of the locator  44  pierces through any fiberglass layers that are positioned over the top of the locator. The locator  44  is used as an alignment feature in the mold  14  with one point used to help keep the insert centered when placed in the mold and the pointed end  56  used to push through fiberglass fabric. The pointed end  56  is received into a second receiving portion  58  in the mold component  34 . 
         [0021]    In a higher temperature molding process, such as a sheet molding compound (SMC) process, the mold components  32 ,  34  are first closed and a mixture of fiberglass strands and a resin are injected into the closed mold  14  and forced into all of the cavities of the mold, including around the insert  12  and the spacer  26 . In the higher temperature process, the locator  44  aligns the insert  12  with respect to the mold  14 . 
         [0022]    In both the cold temperature and higher temperature molding processes, the locator  44  keeps fiberglass or other materials from contaminating the interior surface  24  of the insert  12 , keeping any threads on the interior surface clean. After the mold has cured, the roof panel  10  with the embedded insert  12  is removed from the mold components  32 ,  34 . The locator  44  is removed from the interior surface  24  of the insert  12 , such as with use of a clamp. 
         [0023]    When the locator  44  is removed, the roof panel  10  can be assembled onto a vehicle in a conventional manner. The insert  12  can receive fasteners to mount vehicle components to the roof panel  10 .