Land vehicles: bodies and tops – Tops – Roof structure
Reexamination Certificate
1999-04-30
2001-09-04
Pedder, Dennis H. (Department: 3612)
Land vehicles: bodies and tops
Tops
Roof structure
C296S216090
Reexamination Certificate
active
06283542
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates to a solar cover of an openable motor vehicle roof with a transparent cover panel which is at least partially surrounded in the edge area by a plastic frame, and which is provided with a solar cell network on the inside of the cover panel which extends into the vicinity of the cover panel edge area, and with an inner cover sheet which is located in the cover panel edge area and which overlaps the solar cell network with its inside edge. The invention also relates to a process for producing such a solar cover.
2. Description of Related Art
A solar cover of the above-mentioned type is known, for example, from German Patent No. DE 40 20 655 C1. In this known solar cover, the outside edge of the inner cover sheet is integrated into the plastic frame; this requires that the inner cover sheet is already attached to the inside of the cover panel when the plastic frame is connected thereto, for example, by foaming on. This is relatively complex. The problem in this known solar cover is, moreover, that the solar cell network extends into the area of the inside of the cover panel that is surrounded by the inner cover sheet which, in this area, is in contact with the solar cell network. This loads the network in a manner detrimental to the endurance strength of the solar cover, since application of a load to the solar cell network over the long run leads to delamination of this network.
Another laminate composite glass pane with embedded solar cells is known from DE-U1 85 35 648.
SUMMARY OF THE INVENTION
In view of this prior art, a primary object of the present invention is to devise a solar cover of the initially mentioned type which can be easily produced and which ensures a long service life without adversely affecting the solar cell network.
In addition, it is a further object to provide a process for easily producing the inventive cover.
These objects are achieved with respect to the solar cover by a gap being left between the inside edge of the inner cover sheet and the solar cell network so that the inside edge of the inner cover sheet remains disengaged from the solar cell network. Furthermore, optionally, the inner cover sheet is securely connected by means of adhesive to the combination of the cover panel and the plastic frame.
These objects are achieved with respect to the process for production of the solar cover by, first of all, the plastic frame being molded to the edge area of the cover before the solar cell network is applied to the inside of the cover, and then the inner cover sheet being cemented to the combination of cover and plastic frame, optionally with contact-free overlapping of the solar cell network.
The core of the invention is accordingly formed by contact-free overlapping of the solar cell network by the inner cover sheet. This contact-free overlapping ensures the endurance strength of the solar cover since, in contrast to the prior art, no forces which lead to delamination of the solar cell network over the long term are applied to the solar cells by the inner cover sheet. On the other hand, the overlapping ensures a sufficiently large useful surface for the solar cell network so that the attainable solar power measured on the surface of the cover is optimum.
According to one advantageous development of the invention, the inside edge of the inner cover sheet, in the solar cell network overlapping area, follows the contour of the overlapped area of the solar cell network in order to ensure as small as possible a structural height of the solar cover in the edge area.
Another key aspect of the invention involves the provision of an adhesive connection of the inner cover sheet to the combination of the cover panel and the plastic frame such that contact between the inner cover sheet and the solar cell network is prevented. The adhesive connection of the inner cover sheet to the combination of the cover panel and the plastic frame, at the same time, enables simplified manufacture of the solar cover because, after completion of the combination of the cover panel and plastic frame, the solar cell network can be laminated onto the inside of the cover panel before attachment of the inner cover sheet without adversely affecting the rubber mat which is necessary for this lamination process, because the plastic frame in the area of its bottom can be made almost as flat as desired. Only after laminating the solar cell network onto the inside of the cover is the inner cover sheet adhesively connected.
The plastic frame can be made so thin that it provides tolerance equalization for the cover panel edge. One advantage of this thin design of the plastic frame is relatively low consumption of the corresponding plastic material, preferably foamable polyurethane. The plastic frame adheres to the cover panel only over the width necessary for the strength of the cover panel.
In the plastic frame, there is advantageously at least one recess that is open towards the adjoining inner cover sheet for holding the adhesive that joins it to the inner cover sheet. This is done by applying and holding the adhesive in the required thickness in a defined manner. Furthermore, it is advantageously provided that, inwardly from the plastic frame on the inside of the cover, an adhesive bead is applied for joining the inner cover sheet to the inside of the cover. This measure makes it possible to connect a wider inner cover sheet to the inside of the cover panel in a stable manner, while insuring that the inner cover sheet is spaced away from the inside of the cover panel far enough to prevent contact between the inner cover sheet and solar cell network.
Advantageously, in the plastic frame, in addition to the recesses for holding the adhesive there can be depressions or openings to border the channels or cavities which are used to hold electric lines or components.
The process for producing the above described solar cover in accordance with the invention is based on the above described adhesive connection between the inner cover sheet and the combination of the cover panel and plastic fame in which, after completion of the combination of the cover panel and plastic frame, the solar cell network can be laminated onto the inside of the cover panel before attachment of the inner cover sheet without adversely affecting the rubber mat which is necessary for this lamination process, because the plastic frame in the area of its bottom can be made almost as flat as desires. Only after laminating the solar cell network onto the inside of the cover is the inner cover sheet adhesively joined such that its inside edge overlaps the solar cell network without contact.
These and further objects, features and advantages of the present invention will become apparent from the following description when taken in connection with the accompanying drawings which, for purposes of illustration only, show several embodiments in accordance with the present invention.
REFERENCES:
patent: 4509791 (1985-04-01), Bienert et al.
patent: 4891913 (1990-01-01), Shimura et al.
patent: 4971308 (1990-11-01), Herlemann et al.
patent: 5466508 (1995-11-01), Brocke et al.
patent: 85 35 648 (1986-03-01), None
patent: 40 20 655 (1991-05-01), None
patent: 40 06 756 (1991-09-01), None
patent: 197 39 615 (1998-12-01), None
patent: 282020 (1989-11-01), None
patent: 404306126 (1992-10-01), None
Nixon & Peabody LLP
Pedder Dennis H.
Safran David S.
Webasto Systemkomponenten GmbH
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