Land vehicles: bodies and tops – Tops – Roof structure
Utility Patent
1999-04-01
2001-01-02
Dayoan, D. Glenn (Department: 3612)
Land vehicles: bodies and tops
Tops
Roof structure
C296S191000
Utility Patent
active
06168231
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention generally relates to plastic panels. More particularly, the present invention relates to plastic vehicle panels that are comprised of more than one piece. More specifically, but without restriction to the particular embodiment and/or use which is shown and described for purposes of illustration, the present invention relates to a two piece injection molded vehicle panel that provides structural rigidity as well as an aesthetic appearance.
2. Discussion
A major trend in the automotive industry is to produce vehicles that are lighter than previous vehicles. This is typically performed in order to achieve the fuel economy benefits inherent in a lighter vehicle. Another major trend in the automotive industry is to produce vehicles that are less expensive to manufacture than its predecessors. This is performed in order to increase the profit margin per vehicle sold in the marketplace. The auto industry has been in a seemingly never-ending struggle to produce vehicles that are lighter and less expensive than previous vehicles.
Vehicle body panels have been in the flux of change in response to these trends. Traditionally, vehicle panels have been made of steel or some type of composite material. The outside of the panel is typically painted and the inside of the panel, those portions adjacent to the passenger cabin of the vehicle, are covered by a plastic trim piece in order to provide an aesthetically pleasing surface for the passengers of the vehicle. Other systems have also been utilized to provide a show surface on both the interior and the exterior of the panel.
Injection molding of a plastic material has been a method for producing parts that reduces the weight and cost of these type of panels. Unfortunately, it is very difficult to provide injection molded plastic in a vehicle panel size sufficient for this type of application. It is difficult to provide molds that are large enough to handle such a large panel. In addition, it is difficult to achieve proper flow through such a large area. This can lead to many problems, one major problem is developing a show surface that is aesthetically pleasing. Typically, larger panels of this type are made from materials or molding operations that require paint to provide an aesthetically pleasing show surface. Painting a panel adds considerable cost to the vehicle and is, therefore, undesirable. Additionally, with injection molding panels, the panels are typically removed with ejector pins which can cause marks on the on the panels as they are still warm and malable from the injection molding process. Not only is it difficult to produce large injection molded plastic pieces, but it is also difficult to provide a plastic part that produces a system that provides structural rigidity as well as an aesthetic appearance acceptable for vehicle body panels.
There is, therefore, a need to provide large plastic panels that can be used on a motor vehicle. Such a panel must meet certain ultra-violet standards, strength standards as well as surface texture standards. There is also a need to provide large plastic panels that possess structural integrity as well as a textured or show surface on both the interior and exterior surfaces such that it does not require paint to be aesthetically pleasing.
SUMMARY OF THE INVENTION
Accordingly, it is a principal objective of the present invention to provide a a vehicle panel system that provides a show surface on both the interior and exterior of the panel.
It is another objective of the present invention to provide a two piece injection molded system that can be effectively combined to produce a panel with enough structural integrity to be utilized as a body panel for a motor vehicle.
It is still another objective of the present invention to provide a plastic vehicle panel that will not deform with high temperature or sun loads.
In one form, the present invention provides a two piece vehicle panel made by injection molding. The panel includes a first piece and a second piece. The first piece includes two longitudinally extending and parallel structures and at least two cross members interconnecting the two structures. The first piece also includes at least one downwardly extending pillars that terminates in a base formation. The base formation is adapted to be secured to the vehicle body via bolts, screws, clips, or the like. The first piece has an inner surface that is suitable for display and an outer surface that has portions thereof suitable for display. The second piece includes a generally planar top surface that attaches to the cross members of the first piece to provide support thereto. The second piece also includes at least one projection extending downward from the planar top surface that is cooperative with the downwardly extending pillar of the first piece to create a structural channel. The second piece has an outer surface that is suitable for display and includes portions of its inner surface that are suitable for display.
The planar top surface of the second piece is directly subjected to sun load due to its relative position with the vehicle, while concealing the cross members and the longitudinal structures from direct sun load. The planar top surface includes a crown so as to prevent sink from prolonged sun load.
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from a reading of the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings.
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Burns John D.
Fielding Russell C.
Hoffmann Bernhard U.
Schroeder Del C.
DaimlerChrysler Corporation
Dayoan D. Glenn
Engle Patricia
Lorelli Marc
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