阅读说明：本技术 多面板可拆装车顶 (Multi-panel detachable vehicle roof ) 是由 帕特里克·达勒姆 小永井祐平 八木穣 马修·普劳曼 埃文·弗里曼-吉伯 休·福伦 于 2020-01-06 设计创作，主要内容包括：一种车辆可拆装车顶系统包括：可拆装地装接至所述车辆的车顶支撑结构,其包括多个竖直定向支撑件和至少一个水平定向支撑件。至少一个可拆装面板被构造为与车顶支撑结构接合。由轻量夹层复合结构形成的车辆可拆装车顶系统提供具有提高的耐湿性的无需在生产之后借助额外加工的高光泽表面以及适合于将可拆装车顶组件密封到其他车辆部件的边缘。(A removable vehicle roof system comprising: a roof support structure removably attachable to the vehicle includes a plurality of vertically oriented supports and at least one horizontally oriented support. The at least one removable panel is configured to engage the roof support structure. A vehicle removable roof system formed from a lightweight sandwich composite structure provides a high gloss surface with improved moisture resistance that does not require additional processing after production and an edge suitable for sealing the removable roof assembly to other vehicle components.)

1. A removable vehicle roof system, comprising:

a roof support structure removably attachable to the vehicle, the roof support structure comprising a plurality of vertically oriented supports and at least one horizontally oriented support;

at least one removable panel formed from a composite sandwich panel assembly, the at least one removable panel configured to engage with the roof support structure.

2. The removable vehicle roof system of claim 1, wherein the composite sandwich panel assembly comprises: a hollow structure core defining a plurality of apertures; a high gloss surface sheet adhered to the first face of the hollow structure core by a first adhesive layer; and a structural skin adhered to the second side of the hollow structure core by a second adhesive layer.

3. The removable vehicle roof system of claim 2, wherein the hollow structural core is an array of hexagonal holes.

4. The removable vehicle roof system of claim 2, wherein the hollow structural core is formed from a cellulosic material.

5. The removable vehicle roof system of any of claims 2 to 4, wherein the high gloss surface sheet is formed from any of: sheet Molding Compounds (SMC), thermoplastic sheets, dicyclopentadiene (DCPD), or coated molded Polyurethanes (PU).

6. The removable vehicle roof system of claim 2, wherein the first adhesive layer contacts an interior volume of the hollow structural core.

7. The removable vehicle roof system of claim 2, wherein the first structural skin is formed from a fiber mat.

8. The removable vehicle roof system of claim 7, wherein the fiber mat comprises unoriented glass fibers.

9. The removable vehicle roof system of claim 7, wherein the second adhesive layer penetrates the glass fiber mat.

10. The removable vehicle roof system of claim 2, further comprising a filler in the pores of the hollow structural core, the filler being at least one of a sound dampening foam, a flame retardant, or a phase change material.

11. The removable vehicle roof system of claim 2, further comprising a decorative layer attached to the structural skin.

12. The removable vehicle roof system of claim 2, wherein the high gloss surface sheet and the structural skin are joined together to form an edge defining a moisture seal.

13. The removable vehicle roof system of claim 12, further comprising a liner disposed between the high gloss surface sheet and the structural skin at the edge.

14. The removable vehicle roof system of claim 1, wherein the horizontally oriented support is coupled to the plurality of vertically oriented supports.

15. The vehicle removable roof system of claim 1, wherein the plurality of vertically oriented supports of the support structure are formed from Sheet Molding Compound (SMC).

16. The removable vehicle roof system of claim 1, wherein the plurality of vertically oriented supports of the support structure are formed of steel, aluminum, magnesium, or an alloy wherein aluminum or magnesium is majority by weight.

17. The removable vehicle roof system of claim 1, wherein the roof support structure is removably attached to the vehicle.

18. The removable vehicle roof system of claim 1, wherein the at least one horizontally oriented support is a roll cage of the vehicle.

19. The removable vehicle roof system of claim 1, wherein the at least one removable panel has a panel flange extending therefrom, the panel flange configured to engage a support structure flange extending from at least a portion of the roof support structure.

20. The removable vehicle roof system of claim 19, further comprising a gasket positioned between the support structure flange and the panel flange.

21. The removable vehicle roof system of claim 1, wherein the at least one removable panel comprises at least one roof panel.

22. The removable vehicle roof system of claim 21, wherein the at least one removable panel comprises structural ribs or corrugations.

23. The removable vehicle roof system of claim 21, wherein the at least one roof panel comprises a plurality of roof panels configured to engage each other and the roof support structure.

24. The removable vehicle roof system of claim 23, wherein the plurality of roof panels are joined to each other at corresponding flanges extending therefrom.

25. The removable vehicle roof system of claim 24, further comprising a sealing gasket between corresponding flanges extending from the plurality of roof panels.

26. The removable vehicle roof system of claim 1, wherein the at least one removable panel comprises at least one window panel.

27. The removable vehicle roof system of claim 1, further comprising a piping system embedded in the composite sandwich panel of the at least one removable panel.

28. The removable roof system of claim 21, wherein the tubing embedded in the composite sandwich panel of the at least one removable panel is aligned with the tubing of the vehicle.

29. The removable vehicle roof system of claim 1, further comprising a duct system embedded in at least a portion of the roof support structure.

30. The removable vehicle roof system of claim 23, wherein the tubing embedded in the roof support structure is aligned with the tubing embedded in the composite sandwich panel of the at least one removable panel.

Technical Field

The present invention relates generally to a vehicle roof assembly and, more particularly, to a multi-panel removable vehicle roof formed from a composite sandwich structural assembly having an intervening hollow structural core supporting matrix and a facing sheet adhered to the hollow structural core to provide at least one surface that meets vehicle exterior surface gloss criteria.

Background

Vehicles, particularly Sport Utility Vehicles (SUVs) and jeep vehicles, having a removable roof assembly are becoming increasingly popular. Such vehicles allow a user to remove the roof from the body of the vehicle when a weather driving experience is desired, and attach the roof to the body of the vehicle when a standard driving experience of closed, protective components is required or desired. Typically, the removable roof assembly is formed of aluminum, steel, or carbon fiber. These materials and common geometries of typical removable roof assemblies result in heavy and bulky components that tend to make removal of such roof assemblies difficult, often requiring assistance from multiple persons during removal, and limiting the occasions where the roof assembly can be removed from the vehicle body.

In an attempt to reduce the overall weight of the vehicle to make the vehicle more fuel efficient and to reduce the weight of the removable roof assembly to make roof removal easier, glass reinforced plastics and composites, including Sheet Molding Compounds (SMC) or Bulk Molding Compounds (BMC), have been introduced to replace metal structures and surface body components and panels. Sandwich structural composites are a special class of composite materials made by attaching two thin but rigid skins to a lightweight but thick core. The core material is typically a low strength material, but its higher thickness provides a sandwich composite with high bending stiffness with an overall low density.

While sandwich constructions have been previously developed to provide strength and reduced weight, the ability to achieve a high quality glossy surface on the exterior of the vehicle, whether the outermost surface is a thermoset resin or a thermoplastic, remains a challenge, making such composites unsuitable for removable roof assemblies. Examples of these attempts are US5,087,500A, US4,803,108A, US8,091,286B2, US4,369,608A, US3,553,054A and WO 2018/202473. It is conventional not to use such a construction where high surface gloss of the vehicle is required, or to rely on an additional outer layer to provide a high gloss outermost layer. Such an outermost layer can be applied after the structure is produced or by in the mold coating, both of which add to the cost and complexity of production.

Another conventional problem in the art is that the structural edges are ineffective and allow penetration of moisture or moisture entrained within the core. In the event of extreme temperatures experienced by the roof assembly, such entrained moisture can shorten the useful life of the structure while at the same time increasing its weight. These problems of moisture penetration are particularly evident in the examples when the core is formed from a cellulosic material such as paper. Furthermore, the edges of conventional sandwich structured composites are often inconsistent with the final vehicle surface requirements, particularly the edge requirements of removable roof assemblies that require weather strips and water management systems that ensure that the vehicle interior and any occupants remain dry in rain and snow conditions.

Thus, there is a need for an improved removable vehicle roof structure formed from a sandwich composite structure that provides a high gloss surface with improved moisture resistance without the need for additional machining after production and an edge suitable for sealing the removable roof assembly to other vehicle components.

Disclosure of Invention

An inventive removable vehicle roof system is provided. The inventive removable vehicle roof system includes a roof support structure and at least one removable panel engaged with the roof support structure. According to an embodiment, a gasket is included to seal the engagement between the support structure and the removable panel. The roof support structure includes a plurality of vertically oriented supports and horizontally oriented supports. At least one removable panel is formed from a composite sandwich panel assembly. The roof support structure and the at least one removable panel each have a flange extending therefrom. A panel flange extending from the removable panel is configured to engage a support structure flange extending from the roof support structure. When the removable panel is engaged with the roof support structure, a sealing gasket is positioned between the support structure flange and the panel flange to seal the removable panel and the roof support structure and prevent water from entering the vehicle interior. The removable panel can be easily removed from the removable roof assembly while leaving the roof support structure in place and attached to the vehicle body. Alternatively, both the removable panel and the roof support structure may be easily removed from the vehicle. Thus, the inventive removable vehicle roof system allows for increased variability and ease of use as compared to prior art removable roof systems. According to an embodiment, a composite sandwich panel assembly is formed by: a hollow structural core defining a plurality of pores; a high gloss surface sheet adhered to a first face of the hollow structure core by a first adhesive layer; and a structural skin adhered to a second side of the hollow structure core by a second adhesive layer. Thus, the inventive removable vehicle roof system is formed from a lightweight sandwich composite structure that provides a high gloss surface with improved moisture resistance without the need for additional machining after production and edges suitable for sealing the removable roof assembly to other vehicle components.

Drawings

The present invention is described in further detail with respect to the following drawings, which are intended to illustrate certain aspects of the invention, but should not be construed as limiting the practice of the invention.

FIG. 1 is a front perspective view illustrating a removable roof system for a vehicle according to an embodiment of the present disclosure;

FIG. 2 is a rear perspective view illustrating a removable roof system for a vehicle according to an embodiment of the present disclosure;

FIG. 3 is a bottom perspective view illustrating an effect view of the bottom/interior of the removable vehicle roof system according to an embodiment of the present disclosure;

FIG. 4 is a front perspective view showing the removable roof system of the vehicle with a portion of the removable panel of the roof system removed;

FIG. 5 is a side view illustrating a removable roof system of a vehicle according to an embodiment of the present disclosure;

FIG. 6 is a detailed side view of the removable vehicle roof system of FIG. 5 showing a seal between a roof support structure and a removable panel of the removable vehicle roof system;

FIG. 7 is a top view illustrating a removable roof system of a vehicle according to an embodiment of the present disclosure;

FIG. 8 is a detail front view showing the seal between portions of the removable panel of the removable roof system of the vehicle;

FIG. 9 is a cross-sectional view of a portion of a roof support structure of a removable vehicle roof system according to an embodiment of the present disclosure;

FIG. 10 is a perspective view, partially cut away, of a composite sandwich component used to form a component of a removable vehicle roof system according to an embodiment of the present disclosure;

FIG. 11 is an enlarged partial cross-sectional side view of the composite sandwich assembly of FIG. 10 along a line bisecting the hexagonal aperture;

12A-12D are cross-sectional views of the edges of the composite sandwich component of FIG. 11;

FIG. 13 is a partially cut away perspective view of a composite sandwich assembly having a ductwork embedded therein according to an embodiment of the present disclosure;

FIG. 14 is a front perspective view illustrating a removable roof system for a vehicle according to an embodiment of the present disclosure;

fig. 15A-15D are detailed cross-sectional views of the removable vehicle roof system of fig. 14.

FIG. 16 is a front perspective view illustrating a removable roof system for a vehicle according to an embodiment of the present disclosure;

FIGS. 17A and 17B are detailed cross-sectional views of the removable vehicle roof system of FIG. 16;

FIG. 18 is a front perspective view illustrating a removable roof system for a vehicle according to an embodiment of the present disclosure; and is

Fig. 19A and 19B are detailed cross-sectional views of the removable vehicle roof system of fig. 18.

Detailed Description

The present invention has utility as an improved removable vehicle roof structure, a removable vehicle roof system formed from a lightweight sandwich composite structure that provides a high gloss surface with improved moisture resistance without the need for additional machining after production and edges suitable for sealing the removable roof assembly to other vehicle components. According to an embodiment, the inventive removable vehicle roof system comprises: a roof support structure; at least one removable panel engaged with the roof support structure; and a gasket sealing engagement between the support structure and the removable panel. The roof support structure includes a plurality of vertically oriented supports and at least one horizontally oriented support. According to an embodiment, the roof support structure is formed at least at a portion of the vehicle structure, such as a roll cage of the vehicle, or the roof support structure is configured to be removably attached to the vehicle body. At least one removable panel is formed from a composite sandwich panel assembly. According to an embodiment, the roof support structure and the at least one removable panel each have a flange extending therefrom. A panel flange extending from the removable panel is configured to engage a support structure flange extending from the roof support structure. When the removable panel is engaged with the roof support structure, a seal gasket may be positioned between the support structure flange and the panel flange to seal the removable panel and the roof support structure and prevent water from entering the vehicle interior. The removable panel can be easily removed from the removable roof assembly while leaving the roof support structure in place and attached to the vehicle body. Alternatively, both the removable panel and the roof support structure may be easily removed from the vehicle. Thus, the inventive removable vehicle roof system allows for increased variability and ease of use as compared to prior art removable roof systems.

According to an embodiment, a composite sandwich panel assembly of removable panels and other components forming the inventive removable vehicle roof system comprises: a hollow structure core (open area core) defining a plurality of pores; a high gloss surface sheet adhered to a first face of the hollow structure core by a first adhesive layer; and a structural skin adhered to a second side of the hollow structure core by a second adhesive layer. Further details regarding the composite sandwich panel assembly forming part of the inventive removable vehicle roof system are described in U.S. provisional application 62/774,600, which is incorporated herein by reference. Notable features of the composite sandwich panel assembly forming part of the removable vehicle roof system of the present invention include reduced delamination of the parts of the inventive sandwich composite structure and reduced penetration of the bond line through the high gloss face sheet due, at least in part, to the viscosity of the applied adhesive forming a greater adhesive contact area between the parts of the inventive sandwich composite structure. In addition, the composite sandwich panel assembly provides a high gloss exterior surface and a waterproof edge without relying on additional processing to prevent the penetration of moisture or vapor that can reduce the operating life of the structure, particularly if the roof assembly is subjected to temperature extremes.

It will be understood that where a range of values is provided, the range includes not only the end values of the range but also the intermediate values of the range that are explicitly included in the range and that vary by the last significant digit of the range. For example, reference to a range from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.

As used herein, the term "high gloss surface" refers to a surface having minimal perceptible surface defects when visually inspected about 24-28 inches from the viewer in a well-lit area and perpendicular to the part surface at +/-90 degrees for about 3 seconds. That is, the term "high gloss surface" refers to a surface that can be painted and is considered a "class a" vehicle body part. This is typically measured by ASTM D523. In the automotive industry, class a surfaces are those that a consumer can see without operating the vehicle (e.g., opening the hood or trunk lid), while class a surface finishes generally refer to painted exterior panels, and specifically to distinctness of image (DOI) and gloss levels on parts. It should be understood that the surface layer may be subjected to sanding, finishing and primer prior to receiving the high gloss imparting coating, but the dimensional and adhesion uniformity of the primer and coating must be maintained in order to achieve a high gloss finish.

Referring now to the drawings, the inventive removable vehicle roof system is generally designated 100. The inventive removable vehicle roof system 100 includes a roof support structure 102 and at least one removable panel 104. According to an embodiment, the vehicle removable roof system 100 further comprises a sealing gasket 106. The roof support structure 102 includes a plurality of vertically oriented supports 108 and at least one horizontally oriented support 110. According to an embodiment, the at least one horizontally oriented support 110 is a roof panel or at least one structural component of a vehicle such as a roll cage 113. According to various embodiments, the roof support structure further comprises a trunk door 103 and/or a vehicle window 105, which may be formed as a vertically oriented support 108, or may be provided as a separate removable panel configured to engage the vehicle and the roof support structure. The at least one removable panel is configured to engage the roof support structure.

According to an embodiment, as shown in fig. 6 and 19B, the at least one removable panel is configured to engage the roof support structure through interaction of a support structure flange 112 extending from the roof support structure 102 and a panel flange 114 extending from the at least one removable roof panel. The roof support structure 102 is removably attached to the body of the vehicle. The at least one removable panel 104, 104' has a panel flange 114 extending therefrom, the panel flange 114 being configured to engage the support structure flange 112 of the roof support structure 102. When the removable panel is engaged with the roof support structure, the seal gasket 106 is positioned between the support structure flange 112 and the panel flange 114 to seal sections of the roof structure and prevent water from entering the vehicle interior. According to a further embodiment, the at least one removable panel 104 is configured to engage the roof support structure through interaction of the panel flange 114' with a horizontally oriented support such as a roll cage 113 of the vehicle, as shown in fig. 17A and 17B.

At least one removable panel 104, 104' is formed from a composite sandwich panel assembly, generally indicated at 10. As will be understood from the description herein, the composite sandwich panel assembly 10 is a lightweight, high strength part having a high gloss surface suitable for exterior automotive finishes. The composite sandwich panel assembly 10 provides reduced part delamination and reduced lines of adhesion through the high gloss face sheet. In addition, the composite sandwich panel assembly 10 provides a waterproof edge to prevent the penetration of moisture or vapor that may reduce the operating life of the structure, particularly in the event of temperature extremes experienced by the roof assembly. According to an embodiment, the sandwich 10 has a hollow structure core 12, the hollow structure core 12 having walls 26 that terminate in faces 27 and 27' that define an ordered array of pores 24. The hollow structural core 12 is positioned between a high gloss surface sheet 14 on one side and a structural skin 16 on the opposite side. As shown in fig. 10, a portion of the high gloss surface sheet 14 is cut away to expose the adhesive layer 20, the cloth material (if present), and the hollow structural core 12. The high gloss surface sheet 14 is bonded to a first side of the hollow structure core 12 by a first adhesive layer 20 and presents an outwardly facing high gloss surface 15. Fig. 11 is an enlarged cross-sectional view of a composite interlayer 10 suitable for forming a component of the removable vehicle roof system 100 according to an embodiment of the present invention, showing further details of the various layers making up the composite interlayer. In some cases, cloth 19 is present between the face 17 of the hollow structure core 12 and the high gloss face sheet 14, the cloth 19 being embedded within the adhesive layer 20. The structural skin 16 is bonded to the second, opposite side of the hollow structural core 12 by a second adhesive layer 22. In some cases, cloth 19 ' is present between face 17 ' of hollow structural core 12 and structural skin 16, with cloth 19 ' embedded within adhesive layer 22. Although the structure 10 depicted in fig. 10 and 11 is planar, it should be understood that the high gloss surface and the structural skin are each formed to have a non-planar profile, respectively.

The hollow structure core 12 is formed of a lightweight material defining a plurality of apertures 24 to reduce the overall density of the hollow structure core 12. The shape of the holes 24 illustratively includes a hexagon, a circle, a diamond, a triangle, a parallelogram, and a regular quadrilateral. The faces 17 and 17' of the hollow structure core 12 support the tensioned high gloss surface sheet 14 and the structural skin 16 when the composite sandwich 10 is assembled and externally applied forces are transmitted within the structure 10. The hollow structural core 12 is formed from a variety of materials including: cellulosic products such as corrugated board, paperboard, paper stock; thermoplastics such as poly (methyl methacrylate) (PMMA), Acrylonitrile Butadiene Styrene (ABS), polyamides, polylactic acid, polybenzimidazole, polycarbonate, polyethersulfone, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and block copolymers of any of the foregoing, wherein at least one of the foregoing thermoplastics comprises a majority of the weight of the copolymer regardless of the tacticity of the polymer or copolymer; thermosetting materials such as polyesters, polyureas, polyurethanes, polyurea/polyurethane, epoxy, vinyl esters; metals, such as aluminum, magnesium, and alloys of any of the foregoing, wherein at least one of the foregoing constitutes a majority by weight of the alloy; foams formed from polyurethane, polyethylene, ethylene vinyl acetate, polypropylene, polystyrene, polyvinyl chloride, or aerogel, whether open or closed cell.

A bore 24 defined by a wall 26 of the hollow structural core 12 extends between the faces 17 and 17'. In some embodiments, the walls 26 are treated to alter their properties, such as hydrophobicity or surface energy, to facilitate adhesion thereto. For example, cellulose articles are readily moisture absorbent and are readily coated with waxes such as paraffin or silicone to make cellulose more hydrophobic than in its natural state. Alternatively, cellulose is readily alkylated by conventional reactions such as with chloroacetic acid. Sarymakkov, A.A et al, chem. nat. comp. (1997)33: 337. The metal is similarly coated with a primer or other corrosion inhibitor. Alternatively, the metal or polymer is plasma treated to alter the surface energy to promote adhesion thereto.

In some embodiments of the invention, the ratio of the thickness of wall 26 to the maximum straight length between faces 17 and 17' is between 0.01-10: 1. In such inventive embodiments, the wall thickness is in the range of 0.1mm to 100 mm.

The high gloss facesheet 14 of the composite sandwich panel 10 forming the removable panel is formed from Sheet Molding Compound (SMC), a thermoplastic material, dicyclopentadiene (DCPD), a overmolded Polyurethane (PU), or a combination thereof. According to an embodiment, the high gloss surface sheet 14 comprises a filler 30 to reinforce the high gloss surface sheet 14 and/or for reducing the weight of the high gloss surface sheet 14. The filler 30 is any one or a combination of glass fibers, carbon fibers, natural fibers, hollow or solid glass microspheres. The fibers may be oriented or non-oriented. In some inventive embodiments in which the SMC forms a high gloss surface, a trade name sold by continental Structural Plastic Inc. (continental Structural Plastic Inc.) is used hereinAndULTRA-LITE^TMthe resin of (3). Exemplary formulations thereof are detailed in US7700670, WO2017/184761 and US7524547B 2. It should be understood that high gloss sheets conventionally include additives for preserving dimensionality. These additives conventionally include glass fibers; carbon fibers; inorganic particulate fillers such as calcium carbonate, talc and carbon black; glass microspheres; a carbon nanotube; graphene; a low profile additive; a water removal agent; and combinations thereof. Typical thicknesses for the high gloss surface sheets of the present invention range from 0.5 to 3.5 millimeters (mm) regardless of edge.

The high gloss surface sheet 14 is bonded to a first side of the hollow structural core 12 by a first adhesive layer 20. The first adhesive layer 20 is formed of a thermoplastic material or a curable formulation. According to certain embodiments of the invention, the first adhesive layer 20 is a polyurethane or polyurethane prepolymer adhesive, which may be in the form of a glue, a moisture-curing adhesive, a reactive hot-melt adhesive, or a polyurethane resin. As best shown in fig. 11, the adhesive layer 20 is designed to have an initial viscosity in contact with the face 27 and the wall 26 to partially fill the pores 24 of the hollow structure core 12 due to the compressive force applied to the first adhesive layer 20 between the high gloss surface sheet 14 and the hollow structure core 12. It will be appreciated that the viscosity at the time of coating is a function of factors including the coating temperature, pore size at the face, and intrinsic adhesive viscosity. The viscosity of the first adhesive layer 20 ensures that the adhesive does not excessively penetrate into the pores defined in the hollow structure core before the adhesive reaches final strength. Thus, the bonding surface area for the bonding between the high gloss surface sheet and the hollow structure core is at least 5% greater than the surface area of the wall at the face. In other embodiments, the bond area to surface area percent (surface area percent) is between 5 and 100, and in other inventive embodiments even 100 surface area percent. This increased bonding surface area reduces delamination of the components of the composite interlayer 10 of the present invention and surprisingly allows for the use of thinner high gloss surface sheets that do not exhibit bond line penetration. By increasing the range of bonding surface area by 10 to 50 surface area percent, the thickness of the relatively expensive high gloss surface sheet is allowed to be reduced from 1.5mm to between 1.3mm and 0.8mm while still maintaining high gloss by preventing the bond lines from penetrating through.

In some embodiments, the cloth 19 is embedded in the first adhesive layer 20. The cloth material can be woven or non-woven, but has sufficient porosity to allow penetration of the adhesive layer 20. The cloth 19 provides a greater surface area for the adhesive layer 20 and reduces the surface tension differential relative to the structural skin 16 associated with conditions such as manufacturing processes, temperature differences in the use environment, and differential force loading during use. The cloth 19 usable here illustratively includes: fibers of a thermoplastic material such as poly (methyl methacrylate) (PMMA), Acrylonitrile Butadiene Styrene (ABS), polyamides, polylactides, polybenzimidazole, polycarbonate, polyethersulfone, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and block copolymers of any of the foregoing, wherein at least one of the foregoing thermoplastic materials comprises a majority by weight of the copolymer regardless of the tacticity of the polymer or copolymer; carbon fibers; a polyaramid; glass fibers in the form of woven, roving or lofty sheets; and mixtures of various fibers. The cloth 19 has a mesh size of 10 to 1000, i.e., the mesh layer has 10 to 1000 openings per square inch. The cloth 19 tends to reduce the effect of the walls 26 on the outward facing appearance of the high gloss surface sheet 14.

The structural skin 16 is adhered to the second side of the hollow structural core 12 by a second adhesive layer 22. The structural skin 16 is formed from a fiber mat, a thermoplastic sheet, or SMC. In some embodiments, the SMC is also a high gloss surface, which is marked in detail with reference numeral 14. In embodiments where the structural skin 16 is a fiber mat, the fiber mat is formed from glass fibers. According to some embodiments of the invention, the fiber mat forming the structural skin comprises non-oriented, non-woven fibers, unidirectional or woven fibers. The structural skin 16 is adhered to the second side of the hollow structural core 12 by a second adhesive layer 22. The second adhesive layer 22 has the properties of the first adhesive layer, which is labeled in detail above with reference numeral 20. In some embodiments, the same adhesive forms both the first adhesive layer 20 and the second adhesive layer 22. In other embodiments of the invention, a cloth 19 'is present in the second adhesive layer 22, the cloth 19' having the properties of the cloth 19 as described in detail above. In some embodiments where both cloths 19 and 19 'are present, cloths 19 and 19' are formed from the same material. In still other embodiments, the cloths 19 and 19' are formed of the same material and have the same thickness. In still other embodiments, the cloths 19 and 19' are formed of the same material, have the same thickness, and are adhered by the same adhesive. In still other embodiments, the surface tension on the high gloss surface sheet 14 and the structural skin 16 are within 10% of each other.

According to embodiments, the thicknesses of the hollow structural core 12, the high gloss surface sheet 14, and the structural skin may vary based on the design parameters and intended use of the finished component of the inventive removable vehicle roof system 100 formed by the present disclosure. As described above, the high-gloss surface sheet 14 has a thickness of 0.5 to 3.5 mm. The ratio of the average thickness of the high gloss surface sheet 14 to the average thickness of the hollow structure core 12 is 0.01 to 1:1, and the ratio of the thickness of the structural skin 16 to the thickness of the hollow structure core 12 is 0.1 to 1: 1. In particular inventive embodiments, the high gloss surface sheet 14 has an average thickness of 1.5 to 5mm and the hollow structure core 12 has an average thickness of 6 to 25 mm. In some inventive embodiments, the average thickness of the hollow structural core 12 is up to 100 mm.

According to some inventive embodiments, decorative layer 29 is attached to an exposed surface 31 of structural skin 16. In some embodiments, decorative layer 29 is an interior vehicle surface. Decorative layer 29 illustratively comprises flocking, a textile, carpet, leather, textured soft-touch plastic, a thermoplastic film, or a combination thereof.

According to certain embodiments of the invention, the composite sandwich panel assembly provides sound attenuation, flame retardancy, thermal insulation, or a combination thereof by placing sound and/or heat absorbing materials within the apertures 24 of the hollow structural core 12. According to an embodiment, the pores 24 of the hollow structure core 12 are at least partially filled with foam particles, flame retardants, or phase change materials. Phase change materials that may be used herein include waxes or inorganic salt hydrates. This feature may help regulate the temperature inside the vehicle in the event that the vehicle removable roof system encounters extreme weather conditions, such as sun, rain, ice, or snow, when installed on the vehicle.

As shown in fig. 12A-12D, respectively, the high gloss surface sheet 14 and the structural skin 16 are bonded together along the edges 33A-33D of the composite sandwich panel assembly to form a seal. In some embodiments of the inventive removable vehicle roof system 100, all edges of the composite sandwich panel assembly 10 are sealed such that the hollow structural core 12 is completely enclosed and moisture is inhibited from entering the interior of the composite sandwich panel assembly 10. In light of the intended use and location of the removable panels and other components of the inventive removable vehicle roof structure 100 formed from the composite sandwich panel assembly 10, it is important to prevent moisture from entering the interior of the composite sandwich panel assembly 10 in view of the expansion and potential failure of the assembly 10 caused by freeze-thaw cycling of moisture within the components. Additionally, in embodiments in which the hollow structural core 12 is formed of a hydrophilic material, such as paper, moisture within the composite sandwich panel assembly 10 can damage the hollow structural core 12 and cause roof panel failure.

Fig. 12A-12D illustrate various embodiments of ways to join the high gloss surface sheet 14 and the structural skin 16 together to form the sealed edges 33A-33D, respectively. In some embodiments, an elastomeric pad 34 is disposed between the high gloss surface sheet 14 and the structural skin 16 at the edge 33C to make the edge 33C more water resistant. It should be understood that the gasket is readily included in the other edge connections 33A, 33B and 33D. The gasket 35 enhances the maintenance of the rim seal over a wide range of use conditions.

According to an embodiment of the inventive removable vehicle roof system 100, a horizontally oriented roof panel 110 of the roof support structure 102 is bonded to a plurality of vertically oriented supports 108. As shown in fig. 4, an embodiment of the horizontally oriented roof panel 110 includes a flange 111 that engages a flange 109 extending from the vertically oriented support 108. According to an embodiment, a sealing gasket is positioned between the flange 109 and the flange 111 to prevent water penetration.

According to an embodiment, the entirety of the roof support structure 102, or a portion thereof, is formed from the same or similar materials of the sandwich composite panel assembly 10 as described above with respect to the removable panel 104, i.e.: a hollow structural core defining a plurality of pores; a high gloss surface sheet adhered to the first face of the hollow structure core by a first adhesive layer; and a structural skin adhered to the second side of the hollow structural core by a second adhesive layer. According to an embodiment of the invention, the horizontally oriented roof panel 110 is formed from the composite sandwich panel assembly 10 to provide the advantages of the lightweight materials with high gloss finish described above, while the plurality of vertically oriented supports 108 are formed from materials conventionally used for removable roof structures, such as SMC, steel, aluminum, magnesium, or aluminum or magnesium-heavy alloys.

According to an embodiment, the at least one removable roof panel 104 is formed of at least two parts 104, 104', 104 ". Providing the removable roof panel 104, 104' in multiple parts increases versatility in use and further reduces the weight of the various components making it easier for a user to remove and attach the roof. According to an embodiment, each portion 104, 104 'has a portion of a panel flange 114 extending from the portion 104, 104' that engages the support structure flange 112 as described above, as shown in fig. 4. Additionally, each section 104, 104 'may have a second panel flange 115, 115' extending therefrom. The second panel flange 115 of the first panel portion 104 is configured to engage with the second panel flange 115 'of the second panel portion 104'. According to an embodiment, a second sealing gasket 116 is positioned between the second panel flanges 115, 115'. According to an embodiment, the at least two portions 104, 104 ', 104 "of the at least one removable roof panel 104 comprise panel flanges 114, 114' configured to engage each other, as shown in fig. 14-15D. According to other embodiments, the at least two portions 104, 104 ', 104 "of the at least one removable roof panel 104 comprise panel flanges 114, 114' configured to engage with roll cages 113 of the vehicle, as shown in fig. 17A and 17B. A sealing gasket may be positioned between the panel flange and the roll cage 113.

The at least one removable roof panel 104 is configured to sealingly but removably engage the roof support structure. According to an embodiment, the at least one removable roof panel 104, 104 ', 104 "is configured to engage with the horizontally oriented support 110 through interaction of at least one flange extending from the roof panel 104, 104', 104" with at least one flange extending from the at least one horizontal support, as shown in fig. 19B. According to further embodiments, the at least one removable roof panel 104, 104 ', 104 "is configured to engage with the horizontally oriented support 110 by interaction of at least one flange extending from the roof panel 104, 104', 104" with the horizontally oriented support 110 itself, according to some embodiments the horizontally oriented support 110 itself is a roll cage 113 of the vehicle, as shown in fig. 19A.

Embodiments of the inventive removable vehicle roof system also include a duct system 120 embedded in at least one of the removable panels 104, 104' and the roof support structure 102. As shown in fig. 13, the ductwork 120 is embedded in the composite sandwich panel assembly 10 forming the removable panel 104 and/or the roof support structure 102. According to an embodiment, the piping system 120 includes pipes or wires molded into the hollow structure core of the composite sandwich. According to an embodiment, the duct system 120 comprises an electrical wire, a ventilation tube or a heating element. Thus, the inventive removable vehicle roof system 100 can include elements such as speakers, lights, vents for adjusting the climate in the vehicle, and defrost elements for removing ice or snow present on the roof. In embodiments where both the removable panel 104 and the roof support structure 102 include portions of the ductwork 120, the portions of the ductwork 120 are arranged such that the portions of the ductwork are connected to form a single connecting ductwork. According to an embodiment, the tubing 120 present in the removable vehicle roof system 100 is aligned with the tubing of the vehicle. That is, the electrical wires, ventilation ducts and/or heating elements present in the removable roof system 100 are connected to function with similar electrical wires, ventilation ducts and/or heating elements in the vehicle.

The foregoing description is illustrative of particular embodiments of the invention, and is not meant to be limiting of its practice. The following claims, including all equivalents thereof, are intended to define the scope of the invention.