Patent Description:
OEMS strive for a low aerodynamic drag coefficient for their electric driven passenger vehicles. A low drag coefficient is beneficial for the driving range which can be reached by one battery charge. Features that increase the drag coefficient such as open windows or open roof systems may negatively influence the range that can be reached by one battery charge. Nevertheless, a possibility for obtaining additional ventilation in the interior is often wished for by occupants. So instead of having an electric vehicle having no open roof construction or a fixed glass panel, the present invention relates to a roof system comprising a fixed glass panel having a ventilation panel which may, when opened, influence the drag coefficient of the vehicle less compared to a traditional open roof construction.

Although roof systems with a fixed or stationary panel and a movable panel, particularly a ventilation panel, are known in the art, see for example <CIT> or <CIT>, they are not provided with a plastic frame, which makes them relatively expensive.

<CIT> discloses a roof module comprising a front cover, a roof opening closable by a roof panel and a stationary rear panel. A support section forming a roof frame may include reinforcement profiles.

<CIT> relates to a composite hybrid roof frame configured to support at least a portion of a roof panel. The vehicle roof system shown in the drawings comprises a movable front panel and a stationary rear panel. The roof frame is made from plastic and is reinforced by a first continuous fibre composite comprising a multidirectional laminate and a second continuous fibre composite comprising a unidirectional laminate.

It is therefore an object of the present invention to provide a roof system in which the disadvantage described above is avoided or at least reduced.

The roof system according to the invention is characterized by the features of the characterizing portion of claim <NUM>.

The reinforcement is arranged only in places where it is necessary. This will be around the ventilation panel. The fixed panel will provide stiffness due to its fixed attachment so that it is not necessary to provide a reinforcement all around it.

The ventilation panel is movable at least between a closed position and a rearwardly and upwardly inclined venting position. However, the ventilation panel may also be movable in another direction, for instance such that the panel is opened by a movement in a vertical direction or that the panel opens at its front edge in an upwardly inclined venting position.

The ventilation panel is positioned behind the first stationary panel and a second stationary panel is positioned behind the ventilation panel. The ventilation position will then be positioned in an area above a generally present interior ceiling console which extends from on lateral side of the vehicle interior to an opposite lateral side, approximately from one B-pillar to the opposite one. The interior console may house parts such as a rollo winding shaft, sensors for the interior, lighting features, displays and transverse reinforcement beams. In this way also the console may be shaped to have ventilation holes such that interior air may travel from the interior via the vent holes in the interior console towards the exit formed by the open ventilation panel.

In a further embodiment, the frame is at least partly surrounding the first stationary panel and the ventilation panel and is formed in one piece, the second stationary panel being attachable partly to the frame and partly to the fixed roof of the vehicle.

In this manner, the roof system is only partially assembled during manufacture of the roof system, the second stationary panel will only be arranged in its position after the rest of the roof system is already positioned in the fixed roof of the vehicle. This is useful in cases where the size of the complete assembly of the first stationary panel, the ventilation panel and the second stationary panel is too large to handle, especially in between the moment of manufacturing at the supplier and of assembly in the body of the vehicle. It may then be better to split up this assembly in a front part and a rear part.

In such a case the vehicle manufacturer may decide to install the first stationary panel and the ventilation panel, which are joined in one piece, in the vehicle body in a first step and to assemble the second stationary panel in a second step.

In another embodiment, frame may surround the ventilation panel, and the first stationary panel is attachable partly to the frame and partly to the fixed roof of the vehicle.

This is the most minimalistic approach in which also the first stationary panel is not completely surrounded by the frame. Generally, the first stationary panel will be fixed to the frame during assembly of the roof system, but it is conceivable that also the first stationary panel is assembled when the frame is already in its position in the fixed roof.

If the reinforcement of the frame also extends in longitudinal direction along at least a portion of the first stationary panel, the panel can be more reliably fixed to the frame during assembly of the roof system.

The reinforcement may also extend in longitudinal direction along at least a portion of the first and second stationary panel, so that both stationary panels can be fixed to the frame during assembly of the roof system.

The reinforcement is preferably configured to be attached to the reinforcement beams in the vehicle roof extending in longitudinal direction. These reinforcement beams are always present in a fixed roof of a vehicle and are therefore the primary point of attachment for the reinforcement in the frame.

The reinforcement may also be configured to be attached to a transverse reinforcement beam in the vehicle roof extending in transverse direction.

If such reinforcement beam is not present in the fixed roof of the vehicle, the frame itself may be provided with a transverse reinforcement beam, which is then attached to the reinforcement beams of the vehicle roof extending in longitudinal direction.

The plastic frame may at least partly be made from polyurethane, which material is often used to encapsulate panels of vehicle roof systems.

A more rigid frame can be obtained if the frame is at least partly made from a plastic chosen from the group containing PBT + ASA (Polybutylene Terephthalate + Acrylonitrile), SMA (Styrene Maleic Anhydride), PP (Polypropylene) and PAG (glass Reinforced Polyamide).

In a further development at least one winding shaft for a windable sunscreen is positioned adjacent to the transverse reinforcement beam.

The invention also includes a vehicle comprising a roof assembly attached to reinforcement beams in a fixed roof of the vehicle, said roof assembly comprising: a frame surrounding at least a part of an opening and attached to at least the reinforcement beams of the vehicle, said frame being made primarily of plastic material, at least a first stationary panel which is at least partly semi-transparent and is at least partly fixed to the frame, at least one movable panel, arranged adjacent to the stationary panel, and a reinforcement integrated in the frame,.

According to the invention, the reinforcement extends at least around an area covered by the movable panel, and along at least a portion of the frame that is attached to the reinforcement beams of the vehicle.

The frame may at least partly surround the first stationary panel and the ventilation panel and is formed in one piece, and wherein the second stationary panel is partly attached to the frame and partly to the fixed roof of the vehicle.

In another embodiment, the frame surrounds the ventilation panel, and the first stationary panel is partly attached to the frame and partly to the fixed roof of the vehicle, while also a second stationary panel may be partly attached to the frame and partly attached to the fixed roof of the vehicle.

Further details and advantages of the roof assembly follow from the below description of the roof assembly with reference to the drawings showing some exemplary embodiments of the roof assembly.

<FIG> shows the upper part of a vehicle, particularly a passenger car. The vehicle may however also be an SUV, a truck, a camper, caravan, or the like. The vehicle has a fixed roof <NUM>, in this case comprising a very large opening <NUM>, in which the roof system is arranged. In the embodiment shown in <FIG> and <FIG>, the roof system includes an at least semi-transparent first or front stationary panel <NUM>, a movable, central ventilation panel <NUM> and a second or rear stationary panel <NUM>. The panels <NUM> - <NUM> are made of glass or of plastic and be made permanently semi-transparent or be provided with a (known) system to vary the transparency of one or more of the panels, for example electronically.

The central ventilation panel <NUM> is quite narrow or short in longitudinal (X) direction. It would also be possible that there are two separate ventilation panels arranged side-by-side in transverse (Y) direction. In the embodiment shown, the ventilation panel <NUM> is movable between a closed position substantially flush with stationary panels <NUM> and <NUM> and an open position, in which the rear side of ventilation panel <NUM> is moved upwardly to a rearwardly and upwardly inclined position. Other movements are conceivable as well.

<FIG>, <FIG> and <FIG> show how the roof system is fixed to longitudinal reinforcement beams <NUM> of fixed roof <NUM> of the vehicle. These longitudinal reinforcement beams <NUM> are also called cantrails. They comprise a horizontal flange <NUM> onto which a frame <NUM> of the roof system can rest. Frame <NUM> is made primarily from plastic, here Polyurethane (PU) but PBT + ASA, SMA, PP and PAG are also available as frame material. A glue bead <NUM> can be used to attached frame <NUM> to fixed roof <NUM>.

Especially <FIG> and <FIG> show that frame <NUM> comprises a reinforcement <NUM>, preferably made of metal, particularly steel. It extends at least along and below the circumference of ventilation panel <NUM> and includes a plurality of cross bars <NUM> leaving a plurality of ventilation openings <NUM>. The reinforcement <NUM> also extends such that it overlaps flanges <NUM> of reinforcement beams <NUM> of fixed roof <NUM>, so that it can be attached thereto, either directly, for example by (spot) welding, or indirectly by means of glue and/or bolts. As is shown in <FIG>, reinforcement <NUM> may be covered by the plastic of frame <NUM> at the position of flanges <NUM>.

<FIG> and <FIG> show that frame <NUM> may carry a seal <NUM> below the whole circumference of movable panel <NUM>. Downwardly extending ribs <NUM> may be provided at the transverse sides of reinforcement <NUM>. The ventilation panel <NUM> is preferably adjusted by an electric motor through an operating mechanism (not shown), positioned either in the middle or on one or both transverse ends of panel <NUM>. Panel <NUM> may also be split inti two panels arranged side-by-side and each having its own operating mechanism.

<FIG> shows that plastic frame <NUM> is also glued by glue bead <NUM> to flange <NUM> at the position where no reinforcement is present. Here, plastic frame <NUM> extends around the whole circumference of panels <NUM> and <NUM>. In this embodiment, the panels <NUM> and <NUM> and frame <NUM> are first assembled into a unit and during manufacture of the vehicle the unit is built into the vehicle, as illustrated in <FIG>. It is also shown there that the vehicle may also be provided with a transverse reinforcement beam <NUM>. This will be further discussed with reference to other embodiments.

<FIG> shows an embodiment in which frame <NUM> is only present around movable panel <NUM> and is provided with short longitudinal protrusions <NUM> only along their longitudinal sides. This small unit will be built into the vehicle first and only then panels <NUM> and <NUM> are glued to the front and rear of frame <NUM> and on the other sides directly to the longitudinal reinforcement beams <NUM> of fixed roof <NUM> and to transverse beams.

<FIG> illustrate an embodiment in which frame <NUM> is provided with two short longitudinal protrusions <NUM> at the rear only. Long longitudinal protrusions <NUM> are arranged at the front of frame <NUM>, such that front panel <NUM> can be glued to frame <NUM> to form a unit, then built into the vehicle and only then rear panel <NUM> is glued to frame <NUM> and directly to the vehicle. As frame <NUM> in this embodiment also does not extend around the whole circumference of front panel <NUM>, this panel will also be partly glued directly to the vehicle.

In the embodiment of <FIG>, frame <NUM> has long protrusions <NUM> in both rearward and forward direction, so that both panels <NUM> and <NUM> can be united with frame <NUM> before the unit is built into the vehicle. Generally, reinforcement <NUM> will extend into either short protrusions <NUM> or long protrusions <NUM>.

<FIG> again show the embodiment of <FIG> as built into the vehicle. <FIG> show the joint where frame <NUM> ends and panels <NUM>, <NUM> are attached directly to flange <NUM> of fixed roof <NUM>. In <FIG> on the right an encapsulation <NUM> of panel <NUM> is attached to frame <NUM> by a glue bead <NUM>. This is already done in the factory of the manufacturer of the roof system. It is further shown in <FIG> that frame <NUM> and encapsulation <NUM> of panel <NUM> are attached to flange <NUM> by glue bead <NUM>. This is done at the manufacturer of the vehicle. To enable this, encapsulation <NUM> includes a step <NUM>, so that the lower side of frame <NUM> and the lower side of encapsulation <NUM> adjacent frame <NUM> are substantially flush, and together they are attached to flange <NUM> by glue bead <NUM>. The same configuration is shown in <FIG> for rear panel <NUM>.

<FIG>, <FIG> are cross sections of the embodiment of <FIG> or <FIG> at the positions of those of <FIG>. It is shown that in <FIG> that encapsulation <NUM> of panels <NUM> and <NUM> carry a seal <NUM> to seal ventilation panel <NUM> in its closed position. There is a wet area <NUM> below seals <NUM> to catch any water seeping through. In <FIG>, frame <NUM> is attached to flange <NUM>, whereas in <FIG> encapsulation <NUM> of panel <NUM> is attached to frame <NUM> by glue bead <NUM>, while frame <NUM> is attached to flange <NUM> of fixed roof <NUM> by glue bead <NUM>.

<FIG> and <FIG> show how panels <NUM> and <NUM> are attached to fixed roof <NUM> at their front at rear sides. Both figures show that panels <NUM> and <NUM> are not only attached with their perimeter encapsulation <NUM> to transverse beams <NUM>, <NUM>, respectively, but also with an additional transverse encapsulation <NUM>, <NUM> spaced from encapsulation <NUM> and attached to a horizontal flange <NUM>, <NUM> at the free edge of transverse beam <NUM>, <NUM>.

<FIG> is a cross section through another embodiment in which sunshades <NUM>, <NUM> are provided, of which a winding roller housing <NUM>, <NUM> for a winding shaft is arranged below the front and rear edge of ventilation panel <NUM>. In this way the rollo sunshades can be moved to a closed position below the respective panel <NUM>, <NUM> to prevent light coming through semi-transparent panels <NUM>, <NUM> from entering the vehicle's interior.

<FIG> show further variations of the roof system having transverse reinforcement beam <NUM> as already shown in <FIG>. In <FIG>, transverse reinforcement beam <NUM> is part of the roof system and is welded or bolted to reinforcement <NUM> of frame <NUM>. This transverse reinforcement beam <NUM> will be glued to longitudinal reinforcement beam <NUM> of fixed roof <NUM>. In <FIG>, transverse reinforcement beam <NUM> is part of the vehicle and therefore welded or bolted to longitudinal reinforcement beams <NUM>. Frame <NUM> is glued to transverse beam <NUM> then.

From the foregoing it will be clear that the invention provides a versatile roof system having low cost and profile, but still allowing ventilation.

Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in expectedly any appropriately detailed structure. In particular, features presented and described in separate dependent claims may be applied in combination and any advantageous combination of such claims and embodiments are herewith disclosed.

Claim 1:
Roof assembly for attachment to reinforcement beams (<NUM>, <NUM>) in a fixed roof (<NUM>) of a vehicle, comprising:
a frame (<NUM>) surrounding at least a part of an opening (<NUM>) and configured to be attached to the reinforcement beams of the vehicle, said frame being made primarily of plastic material,
a first stationary panel (<NUM>) which is at least partly semi-transparent and is at least partly fixed to the frame,
at least one movable panel (<NUM>), arranged behind the first stationary panel (<NUM>), which movable panel (<NUM>) is movable at least between a closed position and a rearwardly and upwardly inclined venting position,
a second stationary panel (<NUM>), arranged behind the at least one movable panel (<NUM>), and
a reinforcement (<NUM>) integrated in the frame,
characterized in that the at least one movable panel (<NUM>) is a ventilation panel which is short in longitudinal (X) direction and in that the reinforcement (<NUM>) extends at least around an area covered by the ventilation panel (<NUM>), and along at least a portion of the frame (<NUM>) configured to be attached to the reinforcement beams (<NUM>) of the vehicle.