阅读说明：本技术 开放式车顶组件的密封的框架部件 (Sealed frame component of open roof assembly ) 是由 G·斯文克尔斯 W·M·T·H·施兰斯 M·内伦 于 2020-03-18 设计创作，主要内容包括：通过以下方法制造用于开放式车顶组件的多件式框架：提供具有边缘以及邻近于所述边缘的第一附接区域的第一框架元件；提供具有第二附接区域的第二框架元件；将所述第一附接区域和所述第二附接区域至少部分地布置于彼此之上；邻近于所述第一框架元件的边缘施加流体密封剂；当所述密封剂仍然至少部分地为流体时,将密封元件施加于所述第一框架元件和所述第二框架元件中的至少一个上以及所述密封剂上；以及使所述密封剂固化以在所述第一框架元件、所述第二框架元件以及所述密封元件之间提供不透流体的密封。因此,以可靠的方式在所述密封元件与所述密封剂之间提供不透流体的连接。(A multi-piece frame for an open roof assembly is manufactured by: providing a first frame element having an edge and a first attachment region adjacent to the edge; providing a second frame element having a second attachment region; arranging the first and second attachment regions at least partially over each other; applying a fluid sealant adjacent an edge of the first frame member; applying a sealing element to at least one of the first and second frame elements and to the sealant while the sealant is still at least partially fluid; and curing the sealant to provide a fluid-tight seal between the first frame member, the second frame member, and the sealing member. Thus, a fluid-tight connection between the sealing element and the sealant is provided in a reliable manner.)

1. A method of providing a frame for an open roof assembly, wherein the method comprises the steps of:

a) providing a first frame element having an edge and a first attachment region adjacent to the edge;

b) providing a second frame element having a second attachment region;

c) arranging the first and second attachment regions at least partially over each other;

d) applying a fluid sealant adjacent an edge of the first frame element;

e) applying a sealing element to at least one of the first and second frame elements and to the sealant while the sealant is still at least partially fluid; and

f) curing the sealant to provide a fluid-tight seal between the first frame member, the second frame member, and the sealing member.

2. A method according to claim 1, wherein step c) comprises attaching the first frame element and the second frame element, preferably by at least one of welding, spot welding, rivetless riveting, gluing and screwing.

3. The method of claim 1, wherein the edge of the first frame element, the surface of the second frame element, and the sealing element enclose a volume, and step d) includes applying a quantity of fluid sealant at a location of the volume, wherein the quantity of fluid sealant exceeds the volume.

4. The method of claim 1, wherein step e) includes disposing the sealing element on at least one of the first and second frame elements and on the sealant of the fluid, and then applying pressure on the sealing element.

5. The method of claim 4, wherein step e) comprises rolling a roller over the sealing element.

6. The method according to claim 5, wherein the sealing element comprises a bottom part in a bottom plane and a main sealing part extending in a direction perpendicular to the bottom plane, the bottom part comprising a first surface and a second surface opposite the first surface, wherein in step e) the first surface of the bottom part is arranged on the sealant and the surface of the roller rolls over the second surface of the bottom part to push the first surface of the bottom part on the sealant.

7. The method of claim 1, wherein step d) comprises:

d1. applying a first sealant of a fluid adjacent an edge of the first frame element;

d2. curing the first encapsulant;

d3. applying a fluid second encapsulant over the cured first encapsulant; and

wherein in step e) the sealing element is applied while the second sealant is still at least partially fluid; and

wherein in step f), the second sealant is cured.

8. The method of claim 7, wherein a second sealant of the fluid is applied over the cured first sealant and at least one of the first frame component and the second frame component.

9. An open roof assembly for a roof of a vehicle, the open roof assembly comprising a frame defining an opening in the roof of the vehicle and a closure member, wherein the closure member is movable from a closed position in which the opening is closed to an open position, and the frame comprises a first frame element, a second frame element and a sealing element, wherein the frame is formed according to the method of claim 1.

10. The open roof assembly of claim 9,

the first frame element has an edge and a first attachment region adjacent to the edge;

the second frame element has a second attachment region;

the first attachment area and the second attachment area are at least partially arranged on top of each other;

cured sealant adjacent to an edge of the first frame element; and

a sealing element arranged on the first frame element, the cured sealant and the second frame element, wherein the sealing element is applied on the sealant while the sealant is still at least partially fluid.

11. The open roof assembly of claim 9, wherein there is a bulge of the sealant near an edge of the sealing element.

12. The open roof assembly of claim 9, wherein a void is formed along an edge of the first frame element and a sealant is disposed in the void, and wherein the sealant extends outside the void.

13. The open roof assembly of claim 9, wherein the sealing element comprises a bottom part in a bottom plane and a main sealing part extending in a direction perpendicular to the bottom plane, the bottom part comprising a first surface and a second surface opposite the first surface, wherein the first surface of the bottom part is arranged on the cured sealant.

14. The open roof assembly of claim 9, wherein the cured sealant comprises a cured first sealant and a cured second sealant.

15. The open roof assembly of claim 9, wherein in the closed position, the closure member is in direct mechanical contact with the sealing element to close an opening in the roof.

Technical Field

The present invention relates to a frame for an open roof assembly, and in particular to a method of providing such a frame.

Background

Open roof assemblies are well known in the art. Known open roof assemblies are arranged on the roof of a vehicle, wherein an opening is provided in the roof. The movable closure member is selectively in either an open position or a closed position. In the open position, the interior of the vehicle is in open contact with the exterior of the vehicle, for example for providing fresh air in the interior. In the closed position, the interior of the vehicle is closed and protected, for example, from rain and other external influences. In known open roof assemblies, the closure member may be (semi-) transparent to allow sunlight to enter the interior when the closure member is in the closed position.

The closure member is disposed on the frame. It is known to provide a single piece frame or a multi-piece frame. In a multi-piece frame, at least two frame elements are arranged next to each other or partly on top of each other. Still as part of the roof, the frame may be partially subjected to water (e.g. rain) and thus a fluid-tight attachment may be required at least in certain locations. Further, when the movable closure member is in the closed position, a seal needs to be present between the frame and the closure member to seal an opening in the roof of the vehicle. Such a seal may be formed by a suitable sealing element arranged around the opening. However, the sealing element may span the transition between the first frame element and the second frame element. Providing a watertight seal at such a crossing of the transition between the sealing element and the frame element has proven to be challenging.

This problem is solved, for example, in DE2014115905a1, DE102007057999B3 and DE102017106751B 3. In each of these disclosures, a sealant is provided in the void between two frame elements. The sealant is cured with a flat surface, wherein the flat surface is flush with the surface of the frame element. Thus, the sealing element may be arranged over a flat and flush surface such that a fluid tight seal is provided.

In practice, providing a sufficiently flat and flush surface at the transition may still be challenging, especially in mass manufacturing. Furthermore, it may be desirable to provide an uneven transition between the first frame element and the second frame element, in which case it may not be practical to provide a surface such that the sealing element may be arranged fluid-tightly over the transition.

Disclosure of Invention

It is an object of the present invention to provide an improved method of applying a sealing element in a fluid-tight manner over a transition between two frame elements, and a frame manufactured according to said method.

In one aspect, the object is achieved with a method of providing a frame for an open roof assembly according to claim 1. In particular, the method according to the invention comprises the steps of: providing a first frame element having an edge and a first attachment region adjacent to the edge; providing a second frame element having a second attachment region; arranging the first and second attachment regions at least partially over each other; applying a fluid sealant adjacent an edge of the first frame member; applying a sealing element onto the first frame element and the second frame element, wherein the sealing element is applied onto the sealant while the sealant is still at least partially fluid; and curing the sealant to provide a fluid-tight seal between the first frame element and the second frame element.

In the method according to the invention, the sealant is in a fluid state when the sealing element is arranged on top of the sealant. The sealing element can thus be arranged and positioned, while the shape of the fluid sealant is adapted to the position of the sealing element. After the sealing element is arranged and positioned, the sealant cures to form a seal in a shape corresponding to the position of the sealing element, thereby ensuring fluid tightness.

In one embodiment of the method according to the invention, step c) comprises attaching the first frame element and the second frame element. The first and second frame elements are attached to each other by means other than the sealant, such that the sealant is not used to provide structural strength, but is merely used to provide a fluid-tight connection. For example, in the first and second attachment regions, the frame elements may be mechanically coupled by a layer of adhesive (glue) or tape. Other suitable attachment methods are welding, spot welding, rivetless riveting, riveting and screwing. Of course, any other suitable method may be apparent to those skilled in the art. Such other attachment methods may be equally well applied depending on the specific requirements of a particular application.

In an embodiment of the method according to the invention, the edge of the first frame element, the surface of the second frame element and the sealing element enclose a volume. In this embodiment, step d) includes applying a quantity of fluid sealant at a location of the volume, wherein the quantity of fluid sealant exceeds the volume. Thus, more sealant is provided than is required to fill the volume. Thus, when arranging the sealing element over the sealant and positioning the sealant, an excess amount of sealant may be pushed aside from under the sealing element. Thus, there is enough sealant to completely fill the volume, while the excess can be easily pushed aside since the sealant is still fluid.

In one embodiment, step d) further comprises applying the fluid sealant along at least a major portion of an edge of the first frame. In a particular embodiment, the sealant is applied along the entire attachment area along an edge of the first frame element and in particular along a portion of the edge arranged above the second frame element.

In one embodiment of the method according to the invention, step e) comprises arranging the sealing element on at least one of the first and second frame elements and on the fluid sealant, and then applying pressure on the sealing element. The sealing element may be adhered using glue, adhesive or tape and may thus be positioned and pressure may then be applied to ensure adhesion to the surface. The same pressure may be applied at the location where the sealing element is arranged above the sealant, so that e.g. as described above, an excess amount of sealant may be pushed aside and/or a good adhesion between sealant and sealing element may be established. For example, step e) may comprise rolling a roller over the sealing element. Such a roll may be a flat roll, or may be an anilox roll or a structured roll. In a particular embodiment, the roller may be shaped in a direction perpendicular to its rolling direction. For example, recessed portions may be provided in the roller to accommodate the sealing element and to prevent the sealing agent from adhering to the sides of the sealing element when the roller passes over the sealing agent. In a particular embodiment, for example, the sealing element comprises a bottom part extending in a bottom plane and a main sealing part extending in a direction perpendicular to the bottom plane, the bottom part comprising a first surface and a second surface opposite the first surface and adjacent to the main sealing part, wherein in step e) the first surface of the bottom part is arranged on the sealant and the surface of the roller rolls over the second surface of the bottom part to push the first surface of the bottom part against the sealant. In this particular embodiment, the roller need not be in contact with the sealant so that the roller can remain clean. This prevents contamination due to residue of the seal adhering to the roller.

During the application of pressure, the fluid sealant under the sealing element may be pushed to the side. Thus, the edge of the first frame element, the surface of the second frame element and the volume between the sealing elements may be completely filled with a fluid sealant.

In one embodiment, step f) comprises activating the curing of the sealant. For example, the activating step includes at least one of heating, applying radiation, blowing air, and applying a curing agent. Although the sealant needs to remain in a liquid phase between the manufacturing step of applying the sealant and the manufacturing step of applying the sealing element, it may be preferable to cure the sealant as quickly as possible after the sealing element is applied. In one embodiment, the sealant may cure or at least harden over time without any specific action. To reduce the curing time, a specific sealant with a corresponding curing regime may be selected so that curing can be initiated. Known methods of curing certain compositions are heating, application of radiation such as Ultraviolet (UV) radiation, blowing or application of a curing agent. Any other method or means may be used depending on the sealant used. The invention is not limited in this respect.

In one embodiment of the method according to the invention, step d) comprises applying a fluid first sealant adjacent an edge of the first frame element; curing the first encapsulant; applying a fluid second encapsulant over the cured first encapsulant. In this embodiment, the sealing element is applied while the second sealant is still at least partially fluid, and the second sealant is cured after the sealing element is applied.

In another embodiment, the fluid second sealant is applied over the cured first sealant and at least one of the first frame component and the second frame component. Thus, the second encapsulant may extend beyond the boundary of the first encapsulant and the volume. The second sealant between the frame component and the sealing element is then pressed to form a very thin layer, and a gradual transition to direct contact between the sealing element and the frame component to provide a fluid tight seal.

In one aspect, the present invention provides an open roof assembly for a roof of a vehicle. The open roof assembly includes a frame defining an opening in a roof of the vehicle and a closure member. The closure member is movable from a closed position in which the opening is closed to an open position. The frame comprises a first frame element, a second frame element and a sealing element, wherein the frame is formed according to the method according to the invention. In particular, the first frame element has an edge and a first attachment region adjacent to the edge; the second frame element having a second attachment region; the first attachment region and the second attachment region are at least partially disposed over one another; the cured sealant is adjacent to an edge of the first frame element; and a sealing element disposed on the cured sealant and on at least one of the first frame element and the second frame element, wherein the sealing element is applied on the sealant while the sealant is still at least partially fluid.

In one embodiment of the open roof assembly, the sealant is raised near an edge of the sealing element. By applying pressure to the sealing element during application of the sealing element, the fluid sealant will move sideways from under the sealing element. Excess amounts of sealant may bulge near the edge and remain bulged after curing. The location of the bumps depends on a number of factors, such as the excess amount of sealant, the pressure applied, the shape of the pressing element, the physical properties of the sealant (e.g., viscosity, surface tension), and possibly other factors. The projections may be considered during design and construction to provide space for such projections.

In one embodiment, a void is formed along an edge of the first frame element and a sealant is disposed in the void, wherein the sealant extends outside the void. In other words, more sealant is applied than the volume in the void. Thus, when the sealing element is arranged on top of the sealant, the sealant can be pressed and pushed to the side.

In one embodiment of the open roof assembly, the sealing element comprises a bottom part in a bottom plane and a main sealing part extending in a direction perpendicular to the bottom plane, the bottom part comprising a first surface and a second surface opposite the first surface, wherein the first surface of the bottom part is arranged on the cured sealant and the second surface is adjacent to the main sealing part.

In one embodiment of the open roof assembly, the cured sealant comprises a cured first sealant and a cured second sealant according to the above-described embodiment of the method of the present invention.

In one embodiment of the open roof assembly, the closure member is in direct mechanical contact with the sealing element in the closed position to close the opening in the roof. The sealing element thus closes the gap between the frame and the closure member, thereby preventing water or air from flowing into the interior of the vehicle.

Drawings

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the invention, are given by way of illustration only, since various changes and modifications within the scope of the invention will become apparent to those skilled in the art from this detailed description with reference to the accompanying drawings, in which:

FIG. 1A illustrates a perspective view of a vehicle roof with an open roof assembly;

FIG. 1B illustrates an exploded view of the open roof assembly of FIG. 1A;

FIG. 2A illustrates a perspective view of a multi-piece frame for the open roof assembly according to FIGS. 1A and 1B;

FIG. 2B shows a cross-sectional view of the attachment of two frame components of the frame of FIG. 2A;

FIG. 2C shows a cross-sectional view taken along line C-C of FIG. 2B;

FIG. 2D shows a cross-sectional view taken along line D-D of FIG. 2B;

3A-3D show cross-sectional views of two frame members illustrating a method of providing a first embodiment of a frame according to the present invention;

FIG. 3E shows a cross-sectional view taken along line E-E of FIG. 3D;

fig. 4A shows a first embodiment of a method step of the method according to the invention;

FIG. 4B shows a second embodiment of the method steps of the method according to the invention;

FIG. 4C shows a third embodiment of the method steps of the method according to the invention;

FIG. 4D shows an embodiment of a seal for use in a third embodiment of the method according to FIG. 4C;

FIG. 4E shows a fourth embodiment of the method steps of the method according to the invention;

FIG. 5 illustrates a cross-sectional view of a second embodiment of the frame of the open roof assembly according to the present invention;

FIG. 6 illustrates a cross-sectional view of a third embodiment of the frame of the open roof assembly according to the present invention;

FIG. 7 illustrates a cross-sectional view of a fourth embodiment of the frame of the open roof assembly according to the present invention;

8A-8D illustrate another embodiment of a method according to the present invention;

9A-9B illustrate yet another embodiment of a method according to the present invention;

10A-10B illustrate in cross-section another embodiment of a method according to the present invention and a fifth embodiment of a frame of an open roof assembly; and

fig. 11A-11F show a further embodiment of a method according to the invention and a sixth embodiment of a frame of an open roof assembly.

Detailed Description

The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like or similar elements throughout the several views.

Fig. 1 shows a vehicle roof 1 having an open roof assembly arranged therein. The open roof assembly comprises a movable panel 2a and a fixed panel 2 b. The movable panel 2a is also referred to as a closing member, since the movable panel 2a is movable over the first roof opening 3a so as to be able to open and close the first roof opening 3 a. The wind deflector 4 is arranged at the front side of the first roof opening 3 a.

In the embodiment shown, the movable panel 2a can be in a closed position, which is a position in which: in this position, the movable panel 2a is arranged above the first roof opening 3a and closes the first roof opening 3a and is therefore generally arranged in the plane of the vehicle roof 1. Further, the movable panel 2a may be in a tilted position, which is a position in which: in this position, the rear end RE of the movable panel 2a is raised compared to the closed position, while the front end FE of the movable panel 2a is still in the closed position. Further, the movable panel 2a may be in an open position, which is a position in which: in this position, the movable panel 2a slides open and the first roof opening 3a is partially or completely exposed.

It should be noted that the vehicle roof 1 shown corresponds to a passenger car. However, the invention is not limited to passenger cars. Any other type of vehicle that may be provided with a movable panel is also contemplated.

Fig. 1B shows the same vehicle roof as shown in fig. 1A with panels 2a and 2B. In particular, fig. 1A shows the open roof assembly in an open position, while fig. 1B is an exploded view of the open roof assembly in a closed position. Further, in this exploded view of fig. 1B, the presence of a second roof opening 3B is shown. The first and second roof openings 3a, 3b are provided in the frame 5 of the open roof assembly. The edge 5a of the frame 5 defines a first roof opening 3 a.

The second roof opening 3b is arranged below the fixed panel 2b so that light can enter the vehicle interior space through the fixed panel 2b, provided that the fixed panel 2b is a glass panel or a similar transparent panel, for example made of a plastic material or any other suitable material. The second roof opening 3b and the transparent or translucent fixed panel 2b are optional and may be omitted in another embodiment of the open roof assembly.

The wind deflector 4 is typically a flexible material, such as a woven or nonwoven fabric having through holes arranged therein, or a mesh or net. The flexible material is supported by a support structure 4a (e.g., a rod or tube-like structure) that is directly or indirectly hingedly coupled to the frame 5 at a hinge 4 b.

The wind deflector 4 is arranged in front of the first roof opening 3a and adapts to the airflow when the movable panel 2a is in the open position. In its raised position, the windscreen 4 reduces the inconvenient noise caused by the air flow during driving. When the movable panel 2a is in the closed position or in the tilted position, the windshield 4 is held downward below the front end FE of the movable panel 2 a.

Typically, when the movable panel 2a slides into the open position, the windscreen 4 is raised by the spring force, and when the movable panel 2a slides back into its closed position, the windscreen 4 is pushed downwards by the movable panel 2 a. In fig. 1A, the movable panel 2a is shown in an open position and the wind deflector 4 is shown in a raised position. In fig. 1B, the movable panel 2a is shown in the closed position and the windscreen 4 is correspondingly shown in a position in which it is held down.

Fig. 1B further shows a drive assembly with a first guide assembly 6a, a second guide assembly 6B, a first drive cable 7 and a second drive cable 8. The first and second guide assemblies 6a, 6b are arranged on respective lateral ends SE of the movable panel 2a and may each comprise a guide and a mechanism. The guide is coupled to the frame 5, while the mechanism comprises a movable part and is slidably movable in the guide. The first and second drive cables 7, 8 are arranged between the mechanism of the respective guide assembly 6a, 6b and the drive motor 9.

The drive cables 7, 8 couple the drive motor 9 to the mechanism of the respective guide assembly 6a, 6b, so that upon operation of the drive motor 9, the mechanism starts to move. In particular, the core of the drive cables 7, 8 is moved by the drive motor 9 to push or pull the mechanism of the respective guide 6a, 6 b. Such drive assemblies are well known in the art and, therefore, are not further elucidated herein. However, any other suitable drive assembly may be employed without departing from the scope of the present invention. Also, in certain embodiments, the drive motors may be operatively arranged between the respective guides of the guide assemblies 6a, 6b and the respective mechanisms, and in such embodiments, the drive assemblies may be omitted entirely.

In the illustrated embodiment, the guide assemblies 6a, 6b may be set into motion by raising the rear end RE of the movable panel 2a, thereby bringing the movable panel 2a into a tilted position. Then, from the tilted position, the guide assemblies 6a, 6b can start sliding to bring the movable panel 2a in the open position. However, the present invention is not limited to such an embodiment. For example, in another embodiment, the movable panel 2a may be moved to a tilted position by raising the rear end RE, while the open position is reached by first lowering the rear end RE and then sliding the movable panel 2a under the fixed panel 2b or under any other structure or element disposed behind the rear end RE of the movable panel 2 a. In further exemplary embodiments, the movable panel 2a may be movable only between the closed position and the tilted position or between the closed position and the open position.

In the illustrated embodiment, the drive motor 9 is mounted near or below the front end FE of the movable panel 2a at the recess 10. In another embodiment, the drive motor 9 may be positioned at any other suitable location or orientation. For example, the drive motor 9 may be arranged near or below the rear end RE of the movable panel 2a or below the fixed panel 2 b.

The control unit 11 is schematically shown and operatively coupled to the drive motor 9. The control unit 11 may be any kind of processing unit as is well known to the person skilled in the art: a software controlled processing unit or a dedicated processing unit such as an ASIC. The control unit 11 may be a stand-alone control unit or it may be operatively connected to another control unit, such as a multipurpose general vehicle control unit. In yet another embodiment, the control unit 11 may be embedded in or part of such a general vehicle control unit. The control unit 11 may be implemented by essentially any control unit suitable, capable and configured to perform the operation of the drive motor 9 and thus the movable roof assembly.

Fig. 2A shows an exploded view of an exemplary embodiment of the frame 5 in more detail. In particular, the illustrated embodiment is a multi-piece frame comprising four frame components: a left side member 51, a right side member 52, a front member 53, and a rear member 54. In the embodiment of the open roof assembly according to fig. 1A and 1B, the multi-piece frame 5 may comprise further or additional frame parts. The present invention is not limited to any particular shape or form of the frame 5. Similarly, the terminology used for the four frame members 51-54 is not intended to be limiting.

Each of the frame members 51-54 has two attachment areas. In particular, left side rail 51 includes a front attachment region 511 and a rear attachment region 512; right side member 52 includes a front attachment area 521 and a rear attachment area 522; front beam 53 includes right and left attachment regions 531 and 532; and rear beam 54 includes a right attachment region 541 and a left attachment region 542. When assembled, the four frame members 51-54 surround the roof opening 3a defined by the inner edges of the frame members 51-54.

To form the frame 5, it is necessary to assemble the four frame parts 51-54 so that fluid, such as rain, cannot enter the interior of the vehicle, for example, through the opening 3 a. Therefore, a sealing member such as a rubber sealing member is usually arranged on the frame 5 and around the opening 3 a. Obviously, the sealing elements span the attachment areas of the respective frame parts 51-54. In particular, sealing at the transition from one frame part to another may be challenging, as explained with reference to fig. 2B.

Fig. 2B shows a cross section of the first frame part 20 and the second frame part 30. The first frame member 20 and the second frame member 30 may be any one of the four frame members 51-54 shown in fig. 2A. The first frame part 20 has a first attachment area 21 and the second frame part 30 has a second attachment area 31. The first and second attachment areas 21, 31 are arranged on top of each other and may be mechanically coupled in any suitable manner as will be described below.

At the transition from the first frame part 20 to the second frame part 30, local height differences are created. In the embodiment shown, the second attachment area 31 has been formed such that the upper surfaces of the first frame part 20 and the second frame part 30 are substantially flush. A sealing element 40, such as an elongate rubber sealing element, is arranged on the first frame part 20 and on the second frame part 30. Due to the shape of the attachment area 31, an open space 41 remains and is enclosed by the surface of the second frame part 30, the edge 22 of the first frame part 20 and the sealing element 40.

Fig. 2C shows a cross-section along line C-C (fig. 2B). The first attachment area 21 and the second attachment area 31 are arranged on top of each other and a sealing element 40 is arranged on the upper surface of the first frame part 20. By way of example, the sealing element 40 is shown as an elongated hollow structure as known in the art, which is deformable under pressure. As shown in fig. 2C, the closure member 2a is arranged on the sealing element 40 when the closure member is in the closed position. The closure member 2a may deform the sealing member 40 slightly to provide a sufficient fluid tight connection. A dry area is formed at the inner side of the sealing element 40 and a wet area is formed at the outer side of the sealing element 40, where water and fluids may be present. The arrangement of the first frame part 20, the second frame part 30 and the sealing element 40 ensures that no fluid can flow from the wet area to the dry area.

As shown in fig. 2D, which is a cross-section along line D-D (fig. 2B), at the location of the volume 41, an open channel remains from the wet area to the dry area. To prevent fluid from flowing from the wet area to the dry area, at least the volume 41 needs to be closed, for example by filling the volume 41 with a sealant.

Fig. 3A-3E show a method according to the invention for ensuring a fluid-tight filling of a volume 41 with a sealant, wherein the method is particularly suitable for being applied in mass production manufacturing.

In a first method step as shown in fig. 3A, a first frame part 20 and a second frame part 30 are provided. The first frame part 20 and the second frame part 30 are arranged such that the first attachment area 21 and the second attachment area 31 are arranged on top of each other. The first and second frame members 20, 30 may then be attached to each other by any suitable method, such as welding, spot welding, riveting, rivetless riveting, and the like. Additionally, to prevent corrosion, it may be preferred that each frame member 20, 30 is first subjected to a corrosion protection treatment, such as by coating or by any other suitable method. The respective frame members 20, 30 may then be attached by a method that does not negatively affect the handling of the frame members 20, 30. Thus, for example, it may be preferable to apply an adhesive or tape or the like to attach the respective frame members 20, 30. The attachment method may be selected based on such considerations that do not affect the pre-processing of the frame components, but other considerations may also be considered. For example, if a fluid-tight attachment is preferred, a particular tape or adhesive or weld may be selected. In any case, the present invention is not limited to the attachment method. Furthermore, in the present invention, it is not necessary for the first and second frame members to be actually mechanically attached.

Fig. 3B shows a state in which the first and second frame members 20, 30 are arranged relative to each other and the volume 41 is formed by an elongated void. The dashed line 42 indicates the sealing level at which the bottom face of the sealing element is to be arranged in a subsequent step.

In a second step, as shown in fig. 3C, the volume 41 is filled with a fluid sealant 43 to a level above the sealing level 42, thereby providing an excess amount of sealant. As should be apparent, the viscosity of the fluid sealant 43 needs to be high enough to prevent excess amounts of the sealant 43 (i.e., the portion of the fluid sealant 43 above the sealing level 42) from flowing over the surface of the first frame member 20 and/or the second frame member 30. Of course, as will be apparent to those skilled in the art, the edge 22 and the surface of the second frame member 30 in the void may have been pre-treated to improve interaction with the fluid sealant 43. For example, primer fluid may be applied prior to application of the fluid sealant 43 to improve adhesion or flow behavior. Further, the application method of the fluid sealant 43 is not limited. The fluid sealant 43 may be applied by manual operation or by automated operation. The amount of pressure applied may be suitably selected by the skilled person such that the volume 41 is sufficiently filled with the fluid sealant 43 to provide a fluid tight connection.

In a third step, as shown in fig. 3D, the sealing element 40 is disposed over the first frame part 20, the fluid sealant 43 and the second frame part 30. The sealing element 40 is arranged and positioned on the fluid sealant 43 such that the fluid sealant 43 is flattened directly below the sealing element 40, thereby providing a fluid tight connection to the bottom surface of the sealing element 40. Further, pressure may be applied on the sealing element 40 such that the fluid sealant 43 may be pressed into the volume 41, thereby ensuring that the volume 41 is completely filled with the fluid sealant 43.

After the third step of applying the sealing element 40, a fourth step is performed to harden or cure the sealant 43 to provide a permanent fluid-tight connection. The sealant 43 may harden by drying over time, but may also promote or initiate hardening/curing. Particularly in mass production, short curing times may be preferred. The method of curing/hardening is not limited and may be appropriately selected by those skilled in the art, for example, according to the selected composition of the sealant. For example, the sealant 43 may be cured/hardened by blowing, heating, applying radiation such as UV radiation for photopolymerization, or applying a curing agent.

In fig. 3E, a cross-section along line E-E (fig. 3D) is shown. As shown, in this embodiment, the fluid sealant 43 is only applied locally beneath the sealing element 40. The fluid sealant 43 has been pushed by the application of the sealing element 40 so that some bulges 44 are created near the sides of the sealing element 40. Also, if the excess amount of sealant 43 is greater, some of the fluid sealant 43 may adhere to the sides of the sealing element 40 when the sealing element 40 deforms under the applied pressure during application. Depending on the composition and properties of the sealant, such sealant material adhering to the sides of the sealing element 40 may or may not affect the deformability of the sealing element 40. If the sealant on the side edges would negatively affect the function of the sealing element 40, it is contemplated that less fluid sealant 43 may be applied or that the application of the sealing element 40 may be performed in a manner that prevents contact between the sealing element 40 and the fluid sealant 43.

An exemplary embodiment of applying a suitable pressure P for applying the sealing element 40 is shown in fig. 4A. In this method step, the roller 60 is rolled over the sealing element 40. For example, the sealing element 40 may be adhered to the surfaces of the first and second frame members 20, 30 by adhesive tape. The application of pressure P by the roller 60 may be beneficial to ensure that the sealing element 40 adheres sufficiently to the surface to provide a fluid tight connection. Further, a roller 60 may be applied to push the fluid sealant 43 into the volume 41 and to push an excess amount of the fluid sealant 43 to the side so as to provide a flush surface and, more importantly, to fluid-tightly span the sealing element 40 across the sealant 43.

It should be noted that the diameter of the roller 60 may be appropriately selected by those skilled in the art. The diameter of the roller 60 may be selected, for example, according to the size of the void 41, wherein the diameter may be selected such that the roller 60 does not deform the sealing element 40 too much at the location of the sealant 43 in the void.

Fig. 4B shows another particular embodiment in which grooves 62 are provided in the roller 60. During use, the sealing element 40 is disposed in the groove 62. In this embodiment, the outer surface of the roller 60 may roll over the surface of the frame parts 20, 30, while the sealing element 40 deforms in a predetermined manner and receives a corresponding predetermined pressure. Further, with a suitably selected cross-section of the groove 62 (e.g., the cross-section shown in fig. 4B), the sides of the sealing element 40 may be retained in the groove 62 upon application of the pressure P. Therefore, the side edges of the sealing member 40 can be protected from the fluid sealant 43. As described above, this may be advantageous for ensuring the function of the sealing element 40.

It should be noted that the size of the opening of the groove 62 in the outer surface of the roller 60 is preferably selected to be not smaller than the width of the sealing element 40, so that the sealing element 40 can easily enter and exit the groove 62 during rolling of the roller 60 and only deform inside the groove 62.

Further, as shown in fig. 4B, a liquid sealant 43 may be applied in a larger portion of the void 41 along the edge 22, for example to support the roller 60. Similar to the embodiment of fig. 3E, the protrusions 44 may be formed near the side edges of the sealing element 40, but the protrusions 44 are formed further away from the side edges of the sealing element 40 in this embodiment than in the embodiment of fig. 3E, because the protrusions 44 are formed at the side edges of the roller 60.

In the embodiment shown in fig. 4C, the liquid sealant 43 is applied in a larger portion of the void 41. Of course, application of the liquid sealant 43 in a larger portion may also be used in the embodiment of fig. 3E and 4B. Similarly, only a partial application of liquid sealant 43 as used in the embodiment of fig. 3E and 4B may also be used in the embodiment of fig. 4C. Within the scope of the invention, the liquid sealant should at least be applied to such an extent that the interspace 41 is sealed under the sealing member 40, so that no liquid can pass through the interspace 41 under the sealing member 40.

Further, in the embodiment of fig. 4C, the seal 40 is provided with a bottom part 40a and a main seal part 40b, which is shown in more detail in fig. 4D. Referring to fig. 4C and 4D, the bottom part 40a extends in a bottom plane that is substantially parallel to the frame and the sealant 43 after the application of the seal 40. The bottom part 40a comprises a first surface which is arranged on the frame and on the sealant 43 after the application of the seal 40. A second surface of the bottom member 40a, opposite the first surface, is disposed adjacent to the primary seal member 40 b. The main sealing part 40b extends perpendicular to the bottom plane and is flexible in this perpendicular direction in order to be able to adapt to a closure member as shown for example in fig. 2C and 2D.

The roller 60 is adapted to the seal 40 with the bottom part 40 a. In particular, the roller 60 is provided with a groove 62 to accommodate the primary sealing component 40b during application of the seal 40, while the outer surface of the roller 60 contacts the second surface of the bottom component 40a, so that the first surface of the bottom component 40a is pushed onto the fluid sealant 43, preferably so that the seal 40 subsequently adheres to the sealant 43 and passes in a straight line across the gap 41.

A fourth embodiment of the method, as shown in fig. 4E, applies a seal 40, wherein the second surface of the bottom part 40a extends on one side of the main sealing part 40b only adjacent to the main sealing part 40 b. This embodiment is suitable for applying the seal 40 if the surface area available for the seal 40 is small or if there is insufficient space available for the roller 60 to apply the seal 40.

Fig. 5 shows another embodiment, wherein the protrusions 44 are arranged at the same position as compared to the embodiment of fig. 4B due to the use of similar rollers 60. However, the void 41 is now filled over its entire length with a sealant 43. Thus, close to the sealing element 40, the sealant 43 is pushed flat and there is a protrusion 44 adjacent to the flat surface. Next to the protrusion 44, the sealant 43 is present in an excess amount as it has been applied. However, in another embodiment, the liquid sealant may be applied over the entire length of the void 41, such that an excess amount of sealant is applied at the location of the sealing element 40, while less of the fluid sealant 43 is applied at any other location.

Fig. 6 shows another embodiment of a frame seal according to the invention. In the embodiment of fig. 6, the first and second frame parts 20, 30 are arranged on top of each other at their respective attachment areas 21, 31 a. The other frame member 35 is arranged above the other attachment area 31b of the second frame member 30. A fluid sealant 43 is filled in the gap between the edges of the first frame part 20 and the third frame part 35, and a sealing element 40 is arranged according to the invention on the surface of the first frame part 20 and the third frame part 35.

Fig. 7 shows a further embodiment in which the respective surfaces of the frame parts 20, 30 on which the sealing element 40 is arranged are not flush. The height difference of these surfaces is bridged by the sealant 43. In particular, the fluid sealant 43 is disposed on the surface of the second frame member 30 against the edge 22 of the first frame member 20. The sealing element 40 is then arranged over the fluid sealant 43 and pushed against the fluid sealant 43, thereby shaping the fluid sealant 43 such that a fluid-tight connection is provided despite the height difference.

Fig. 8A-8D show another embodiment of the method according to the invention, and in particular an embodiment of the second step of the method described above. Thus, this embodiment starts with the first step as described above and as shown in fig. 3A and 3B. Then, in a second step and as shown in fig. 8A, a first sealant 431 is applied in the volume 41. The level of the liquid first sealant 431 may be only slightly below the sealing level 42 and up to the sealing level 42. Preferably, the level of the first sealant 431 is not higher than the sealing level 42. For example, the liquid first sealant 431 is applied, and then the liquid first sealant 431 is smoothed to a level equal to or lower than the sealing level 42. The first sealant 431 is then first cured or otherwise hardened.

As shown in fig. 8B, on top of the cured first sealant 431, a second sealant 432 is applied in a liquid state, wherein the level of the liquid second sealant 432 is higher than the sealing level 42. When the first sealant 431 is filled to a level close to the sealing level 42, only a small amount of the second sealant 432 needs to be applied.

In a third step, as shown in fig. 8C, the sealing element 40 is arranged on the first and second frame parts 20, 30 and over the liquid second sealant 432. In one embodiment, as described above, pressure may then be applied. The second encapsulant 432 fills any volume between the sealing element 40 and the cured first encapsulant 431. Since only a few second sealants 432 are used and only a small height difference remains between the cured first sealant 431 and the sealing member 40, the application process may be better controlled to prevent the second sealant 432 from adhering to the side of the sealing member 40. Further, since a substantial portion of the sealant has cured and hardened, further manufacturing is less disturbed or dependent on the fluid (second) sealant.

The resulting cross-section along line D-D is shown in fig. 8D. For purposes of illustration, the level of the first sealant 431 is drawn to be significantly lower than the sealing level, thereby showing a small portion of the edge 22 of the first frame member 20. The second sealant 432 fills a gap between the sealing member 40 and the first seal 431. For mechanical and positional stability of the sealing element 40, it may be preferred to provide sufficient fluid second encapsulant 432 to support the entire bottom surface of the sealing element 40, whereby the protrusions 44 may be created. However, this is not necessary or necessary to obtain a fluid tight connection.

Fig. 9A and B show another embodiment. Although in the embodiment of fig. 8A-D, the second encapsulant 432 is applied over only the first encapsulant 431. In the embodiment of fig. 9A-9B, the liquid second sealant 432 may be applied not only to the first sealant 431, but also to the first frame member 20 and/or the second frame member 30.

When applying the sealing element 40, the second sealant 432 may be pressed sideways, and only a very thin layer of the second sealant 432 may remain between the frame part 20, 30 and the sealing element 40, so that the transition to the portion between the sealing element 40 and the frame part 20, 30 where the second sealant 432 is not present has almost no height difference, and thus fluid tightness is ensured.

Fig. 10A and 10B illustrate another embodiment of the method and a fifth embodiment of the open roof assembly, wherein the method step of applying a fluid sealant adjacent to an edge of the first frame element may be performed before or simultaneously with the step of at least partially arranging the first and second attachment areas on top of each other. As shown in fig. 10A, an amount of first sealant 431 may be provided on the second frame element 30 in the second attachment region 31.

Then, the first attachment area 21 of the first frame element 20 is arranged on the first sealant 431. However, the volume of the amount of the first sealant 431 exceeds the volume available after the first frame member 20 is disposed on the second frame element 30. As a result, the amount of the first sealant 431 is pressed as shown by an arrow P1 (fig. 10A), so that the first sealant 431 is upwardly convex as shown by an arrow P2 (fig. 10B), and is disposed adjacent to the edge of the first frame element 20. Also, the amount of the first sealant 431 is selected such that the first sealant 431 protrudes from the space between the first and second frame members 20, 30.

As shown in fig. 10B, the sealing element 40 is then applied over the at least partially fluid first sealant 431.

Fig. 11A-11F illustrate another embodiment of the method and a sixth embodiment of the open roof assembly, wherein the amount of sealant 431 is reduced as compared to the fifth embodiment.

Fig. 11A shows a top view of the first frame element 20 and the second frame element 30 in an unattached state. The first frame element 20 is provided with a notch 201 in the first attachment area 21. A first strip 431a of sealant is disposed in the second attachment region 31 substantially parallel to an edge of the second frame element 30, as also shown in the cross-sectional view of fig. 11C taken along line C-C. A second strip 431B of sealant is disposed substantially perpendicular to the edge at a location corresponding to the intended location of the slot 201, as also shown in the cross-sectional view taken along line B-B of fig. 11B. The amount of sealant of the second strip 431b is suitably selected to be greater than the volume between the slot 201 and the second frame element 30 after attachment of the two frame elements 20, 30. Then, an amount of sealant from the first and second strips 431a and 431b fills the slot 201 and other spaces between the first and second frame elements 20 and 30 adjacent to the slot 201. The excess amount of sealant is pressed to a level above the level of the surfaces of the first and second frame members 20, 30.

Fig. 11D shows a top view of the first and second frame elements 20, 30 after the sealing element 40 is attached and applied. The contour of the sealing strips 431a, 431b and of the second frame element 30 (which-in this top view-is below the first frame element 20 or below the sealing element 40) is indicated by dashed lines. The first and second attachment areas 21, 31 are arranged on top of each other and the first strip 431a of sealant is pressed such that a fluid tight connection is provided between the first frame element 20 and the second frame element 30, as shown in the cross-sectional view of fig. 11F.

As shown in the cross-sectional view of fig. 11E, the notch 201 is filled with a sealant 431. The sealant 431 of the first and second strips 431a and 431b is pressed between the edge of the first frame member 20 (the edge including the notch 201) and the second frame member 30. The sealing element 40 is arranged above the sealant 431, while the sealant 431 is still in the liquid state, so that a fluid-tight crossing of the sealing element 40 is obtained.

It should be noted that in the fifth and sixth embodiments, a predetermined distance is provided between the first attachment area 21 and the second attachment area 31 to at least partially accommodate a quantity of the sealant 431. Further, in these embodiments, the space between the first attachment area 21 and the second attachment area 31 is closed by a ridge at the edge of the second attachment area 31. Both aspects provide for proper control of the flow of sealant 431 when the two frame members 20, 30 are pushed together. Thus, these two aspects are only optional features and may be omitted as required. Further, the sealant 431 may also serve as an adhesive, but within the scope of the present invention, the sealant 431 only needs to provide a fluid tight seal. Other means may be applied to the mechanical coupling as described herein.

Specific 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 virtually 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 is therefore disclosed.

Further, it is contemplated that the structural elements may be generated by applying three-dimensional (3D) printing techniques. Thus, any reference to a structural element is intended to encompass any computer-executable instructions that direct a computer to create such a structural element via three-dimensional printing techniques or similar computer-controlled manufacturing techniques. Moreover, any such reference to structural elements is also intended to encompass a computer-readable medium carrying such computer-executable instructions.

Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention. The terms "a" or "an," as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.