WO2013141844A1

WO2013141844A1 - Roof assembly

Info

Publication number: WO2013141844A1
Application number: PCT/US2012/029765
Authority: WO
Inventors: Steven John JUST; Theodore Joseph SIEGEL; Arnold SPIETH; Justin Adam TIEDT
Original assignee: International Truck Intellectual Property Company, Llc
Priority date: 2012-03-20
Filing date: 2012-03-20
Publication date: 2013-09-26

Abstract

A roof assembly comprises a roof shell having an interior surface that is contoured to direct water along a predetermined path and a roof reinforcement structure that supports the roof panel. The roof reinforcement member of the reinforcement structure has a channel for transporting water and an outlet. A bond flange attaches the roof shell to the reinforcement member and an inlet in the bond flange is disposed to intersect the predetermined path. A water collection area collects water from the outlet and a drain hole removes the water from the collection area.

Description

ROOF ASSEMBLY

BACKGROUND

[0001] Many truck cabs, including sleeper cabs, include an aerodynamic roof assembly that sits on top of the rest of the cab. The outer skin of the roof assembly is sloped toward the front of the cab. Modern manufacturing techniques usually attach the roof assembly to the cab in white with tight tolerances, often using adhesives to fasten the component pieces together. This results in cabs and sleeper units that, in the absence of forced air circulation, limit the amount of airflow through the sleeper unit and allow for the build-up of substantial water vapor throughout the cab and the sleeper. In cold environments, this water vapor contacts the colder portions of the cab, and the water vapor condenses or freezes on the internal surfaces of the cab.

[0002] As the cab subsequently heats up, the frost melts and the water pools in portions of the cab and the sleeper. This build-up of condensation may be exacerbated by the fact that drivers can be prohibited from idling their engines, which is commonly used to provide heat and forced air circulation. Over the course of several days, the amount of water may accumulate to the point that the water, through the movement of the truck, flows to unwanted areas, possibly even landing on the driver.

SUMMARY

[0003] According to one aspect, a roof assembly comprises a roof shell having an interior surface that is contoured to direct water along a predetermined path and a roof reinforcement structure supporting the roof shell. At least one roof reinforcement member of the roof reinforcement structure includes a channel for transporting the water and a bond flange for attaching the roof shell to the reinforcement member. The channel has an outlet, and the bond flange has an inlet that is disposed to intersect the predetermined path. The roof assembly has a water collection area for collecting water from the outlet and a drain hole in the water collection area.

[0004] An additional aspect provides a roof assembly comprising a roof shell having an interior surface. A roof reinforcement structure is disposed interiorly of the roof shell and is attached to the interior surface of the roof shell. The roof reinforcement structure includes at least one generally U- shaped reinforcement member having opposed bond flanges for attachment to the interior surface of the roof shell. A channel of the reinforcement member spaces apart the bond flanges and the channel of the reinforcement member to form a condensate drainage path through the reinforcement member. An inlet is formed through an opening in a bond flange to provide access to the channel. An outlet is formed in the reinforcement member in communication with the channel. The condensate drainage path joins the inlet to the outlet.

[0005] Another embodiment provides a- method of removing water from a roof assembly. In this method, water is directed along an interior surface of a roof shell toward a roof reinforcement having a channel for transporting water. The water flows into the channel of the roof reinforcement., The water flows through the channel. The water drains through an outlet in the channel. In some embodiments, the water flows over a water-resistant insulation layer toward the roof reinforcement.

[0006] In a fourth aspect, a roof assembly for a truck cab comprises a roof shell having an interior surface and a side panel and a roof reinforcement structure disposed to be interior to the roof shell. The roof reinforcement structure is attached to the interior surface of the roof shell and includes an elongate side reinforcement member with at least one bond flange. The bond flange attaches the side reinforcement member to the interior surface of the roof shell, and an interior wall of the side reinforcement member extends upwardly from the bond flange. The side reinforcement member is disposed at a substantial angle to the vertical such that the interior wall of the side reinforcement member and the interior surface of the side panel act as a condensate collection trough, such that water condensing on the interior surface of the side panel above the trough collects in the trough. An outlet is disposed such that the water collected in the collection trough may drain through the outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is an isometric top view of a roof assembly according to a first aspect; [0008] Figure 2 is an isometric top view a roof support structure;

[0009] Figure 3 is an isometric top view of a roof support structure showing an upper reinforcement, a back reinforcement, a front reinforcement, side reinforcements, water collection area, and condensate collection paths;

[0010] Figure 4 is a detail of Figure 3, showing a portion of a water collection area, a drain hole, and a side reinforcement;

[0011] Figure 5 is a bottom isometric view showing the roof reinforcements shown in Figure 3 as attached to the roof shell;

[0012] Figure 6 is a bottom view of the roof shell shown in Figures 2 and 5, showing a representative character line in the roof shell;

[0013] Figure 7 is a top view of a roof reinforcement showing an interior trim attachment hole and a raised rib surrounding the interior trim attachment hole; [0014] Figure 8 is a top view showing an interior trim attachment hole and a raised rib partially surrounding the interior trim attachment hole;

[0015] Figure 9 is a transverse sectional view taken substantially along Line 9 - 9 of Figure 1, showing the polymer backed insulation adjacent the roof shell and the roof reinforcement structure; and

[0016] Figure 10 is a flow diagram showing a method of removing water from a roof assembly.

DETAILED DESCRIPTION

[0017] Figure 1 shows a vehicle or truck roof assembly, indicated generally at 100, for attachment to the top of a vehicle cab. The roof assembly 100 sits on top of the cab roof (not shown) and has a roof shell 102, or panel that is designed to minimize the wind resistance of the tractor cab as it travels. The forces on the roof assembly 100 are such that the assembly is generally reinforced to provide the desired amount of rigidity. As used herein, the term "roof shell" 102 includes the sloped portions of the shell 102 as well as the side panels 106. The roof shell 102 may have a character line 104, at least a portion of which is oriented in a fore and aft direction and proceeds from the back to the front, down the slope of the roof shell 102. A representative roof assembly is shown in Figure 1.

[0018] Figure 2 shows a roof reinforcement structure, indicated generally at 200. An upper reinforcement member 202 supports an upper portion of the roof shell 102 and a front reinforcement member 204 supports a forward portion of the roof shell 102. Two side reinforcement members 206 support the sides 106 of the roof panel 102 and a back reinforcement member 208 supports the back portions of the shell 102. A lower circumferential portion 210, or racetrack, connects the bottom portions of the front reinforcement member 204, the side reinforcement members 206, and rear reinforcement member 208. The roof reinforcement structure 200 shown in Figure 2 does not provide any condensate drainage.

[0019] Referring to Figures 1 and 3, a roof reinforcement structure, indicated generally at 300 of Figure 3, is disposed to be interior to the roof shell 102. The roof reinforcement structure 300 supports the roof shell 102 with an upper reinforcement member 302 that extends laterally across the structure 300, a front reinforcement member 304 that extends downwardly from the upper reinforcement 302, and side reinforcement members 306 that extend between the upper reinforcement member 302 and a back reinforcement member 308. The back reinforcement member 308 extends between the side reinforcement members 306 and a lower circumferential portion 318, or racetrack, that connects the lower portions of the front reinforcement member 304, the side reinforcement members 306, and the rear reinforcement member 308. Figure 3 also shows a side reinforcing member 312 that is disposed to be forward of the side reinforcement members 306. While the reinforcement structure 300 is shown as being comprised of top, front side, and back reinforcement members, different configurations of individual reinforcing members, or even a unified construction, may be used.

[0020] Referring to Figures 1, 3, and 5 and the method (1000) shown in Figure 10, the roof shell 102 has one or more character lines 104 that are contoured, or formed (1002) into the inside surface of the roof shell 102 to direct (1004) the water along one or more predetermined paths 322, 502 along the inside surface of a roof shell 102 toward a roof reinforcement member. A character line 104 is a fold, a corrugation, or any other feature on the interior surface 602 (see Figure 6) of the roof shell 102 that causes the water to flow in a predetermined path toward a roof reinforcement member. More specifically, the corrugation may be downwardly sloped and in fluid communication with a channel 804 of a reinforcing member.

[0021] The bond flange 806 of a given reinforcement member attaches the roof shell 102 to the reinforcement member and has one or more inlets 316 (see Figures 3, 5, and 8) that are disposed to intersect the predetermined path or paths 322, 502, such that water can flow (1008) into a channel 804 of the respective roof reinforcement and be transported within the reinforcing member. As can be seen in Figure 8, the inlet 316 can be formed by an interruption in the attachment of the bond flange 806 to the roof shell 102. Once in the channel 804, the water flows (1010) through the channel 804 to an outlet 314 of the roof reinforcement member or members 302, 304, 306, 308, 312. Thus, the channel 804 forms a portion of a condensate drainage path 320 through the reinforcement member before collecting (1012) in a water collection area 310, which is described in more detail below.

[0022] As shown in Figure 8, the reinforcement may be generally U-shaped, with opposed bond flanges 806 that attach the interior surface 602 of the roof shell 102 to the reinforcement member. In this configuration, the bond flanges 806 are spaced apart by the channel 804.

[0023] Figure 3 shows that the reinforcements 302, 304, 306, 308, 312, when installed, may have a slope that is sufficient to prevent the formation of any water collection points within the roof reinforcement. More specifically, the condensate drainage paths 320 have elevations that monotonically decrease from the inlet 316 to the outlet 314. This reduces the possibility for corrosion and ensures smooth water flow.

[0024] Once the water is collected (1012) from the outlets 314 in a water collection area 310, it may be drained (1014) through a drain hole 402 in the collection area 310 to a point outside of the vehicle. Figures 3 and 5 show representative flow paths 320, 502 of the water as it flows through the channels 804 of the reinforcements and lower circumferential portion 318, and on the underside of the roof shell 102, respectively. It should be noted that the flow paths 320, 502 illustrated in Figures 3 and 5 are only representative flow paths that are provided for the sake of clarity, and they are not intended to limit the design to any particular flow path or in any fashion.

[0025] As shown in Figures 3 and 4, all or a portion of the racetrack 318 may be used as the water collection area 310. The racetrack 318 is typically attached to the cab in white (not shown) located below it with sealed rivet nuts (not shown).

[0026] Figure 4 is a magnified detail of the water collection area 310 and the side reinforcements 306, 312. The drain hole 402 in the water collection area 310 is below the side reinforcement 312. In contrast to the U-shaped member of Figure 8, the side reinforcement 312 is an elongate reinforcement member and has a bond flange 806 that is affixed to the interior surface 602 of the roof shell 102 (not shown) on three sides. An interior wall 404 that is laterally and inwardly displaced from the inside surface of the roof shell 102 extends upwardly from the bond flange 806 such that the side reinforcement member is disposed to be at a substantial angle to the vertical. See Figure 9 for a cross sectional view of a similar configuration on the side reinforcement member 306.

[0027] Thus, a gap, or slot 408, between an upper edge 406 of the wall 404 and the roof shell 102 acts as the inlet 316. The interior wall 404 and the interior surface 602 of the side panel 106 act as a condensate collection trough, such that water condensing on the interior surface 602 of the side panel 106 above the trough 804, or channel is collected in the trough (see 322, 502 Figures 4, 5, and 9). The water then drains through the outlet 314, which, as above, may be an interruption in the attachment of the bond flange 806 to the roof shell 102, and collects in the collection area 310. See flow path 410 in Figure 4. [0028] Figure 5 shows the roof assembly 100 from below, including representative flow paths 320, 322, 502 along the inside surface of the roof shell 102 and within the roof reinforcements and the racetrack 318. Figure 6 is a bottom view of the roof shell 102 showing a representative character line 104 and a representative flow path 322 of the water down the interior surface 602 of the roof shell 102. As discussed previously, the illustrated character line 104 is only one of many potential character lines 104 and is not intended to limit the disclosure or the claim scope.

[0029] Figures 7 and 8 are details showing interior trim attachment points, indicated generally at 700 and 800, for attaching fixtures (not shown) to the inside of the roof assembly 100. Figure 7 shows that attachment holes 702 can be substantially surrounded by a raised boss 704, or rib, that prevents water that has collected or condensed on the inner surface 706 from flowing into the attachment holes 702. If the direction of the water flow, as indicated by the arrow in Figure 8, is known, the raised boss or rib 802 need not necessarily extend all the way around the attachment hole 702.

[0030] Figure 9 is a cross-section along Line 9-9 of Figure 1 and shows a side reinforcement member 306 and upper reinforcement member 302, as well as a water resistant layer 902 that is disposed to be adjacent to the interior surface 602 of the roof shell 102 and the respective reinforcement members 302, 306. The water resistant layer 902 aids in the directing (1004) of the water along the predetermined path 904 by flowing (1006) the water toward the roof reinforcement member 306. The water resistant layer 902 may be spaced from the inner surface of the roof shell 102 by a gap 906 to ensure the free flow of the water along the path 904.

[0031] Further, the water resistant layer 902 may be a water-resistant or water-impervious film, and more particularly, a polymer film that has been incorporated onto an insulating layer as backing. This insulating layer may be inserted between the wall 404 and the interior surface 602 of the roof shell 102 as shown in Figure 9. In this way, water can be channeled into the reinforcements and disposed of properly.

[0032] As described above, water from the reinforcements 302, 304, 306, 308, 312 collects (1012) to the water collection area 310, which may be located in the lower circumferential portion 318, or racetrack. From there, one possible route for disposing the water is to direct the water through the drain hole 402, through the B-pillars (not shown), and out of an e-coat drain hole that has been formed in the bottom of the B pillar. The water may then be drained to the exterior of the cab.

[0033] In summary, the described apparatus and method allow for the efficient removal of water from the cab and roof reinforcement, safely draining the water to an exit point of the vehicle. This not only reduces the potential for corrosion within the cab, but also reduces the likelihood that the water will flow onto the driver.

[0034] 100 - roof assembly

[0035] 102 - roof panel

[0036] 104 - character line

[0037] 106 - roof side panel

[0038] 200 - roof reinforcement structure

[0039] 202 - upper reinforcement

[0040] 204 - front reinforcement

[0041] 206 - side reinforcement [0042] 208 - back reinforcement

[0043] 210 - racetrack

[0044] 300 - roof reinforcement structure

[0045] 302 - upper reinforcement

[0046] 304 - front reinforcement

[0047] 306 - side reinforcement

[0048] 308 - back reinforcement

[0049] 310 - water collection area

[0050] 312 - side reinforcement

[0051] 314 - outlet

[0052] 316 - inlet

[0053] 318 - racetrack

[0054] 320 - flow path

[0055] 322 - flow path

[0056] 402 - drain hole

[0057] 404 - wall

[0058] 406 - upper edge [0059] 408 - slot

[0060] 410 - flow path

[0061] 502 - flow path

[0062] 602 - interior surface of roof shell

[0063] 700 - trim attachment point

[0064] 702 - attachment hole

[0065] 704 - raised boss

[0066] 706 - reinforcement surface

[0067] 800 - trim attachment point

[0068] 802 - raised boss

[0069] 804 - channel

[0070] 806 - bond flange

[0071] 902 - water resistant layer

[0072] 904 - flow path

[0073] 906 - gap

[0074] 1000 - method of removing water from a roof assembly

[0075] 1002 - forming a character line [0076] 1004 - direct water along predetermined path

[0077] 1006 - flow water into reinforcement channel

[0078] 1008 - flow water through reinforcement channel

[0079] 1010 - collect water

[0080] 1012 - drain water

Claims

We claim:

1. A roof assembly comprising:

a roof shell having an interior surface contoured to direct water along a predetermined path; a roof reinforcement structure supporting the roof shell, at least one roof reinforcement member of the roof reinforcement structure having

a channel for transporting the water, the channel having an outlet;

a bond flange for attaching the roof shell to the reinforcement member, the bond flange having an inlet disposed to intersect the predetermined path;

a water collection area for collecting water from the outlet; and

a drain hole in the water collection area.

2. The roof assembly of Claim 1, further comprising a water-resistant layer disposed to adjoin the reinforcement structure and be proximate to the interior surface of the roof shell, the water-resistant layer aiding in the direction of the water along the predetermined path.

3. The roof assembly of Claim 1, wherein the water-resistant layer is polymer-backed insulation.

4. The roof assembly of Claim 1 , wherein the inlet is formed by an interruption in the attachment of the bond flange to the roof shell.

5. The roof assembly of Claim 1, wherein the roof reinforcement, when installed, has a slope sufficient to prevent the formation of a water collection point within the roof reinforcement.

6. The roof assembly of Claim 1, wherein the roof reinforcement is a side reinforcement and the inlet is a slot, the side reinforcement comprising a wall affixed to the roof shell on three sides and an upper edge laterally and inwardly displaced from the roof shell such that the upper edge and the roof shell form the slot and the wall and the roof shell form the channel.

7. The roof assembly of Claim 1, further comprising an interior trim attachment hole in the roof reinforcement and a raised rib disposed to at least partially surround the interior trim attachment hole to prevent water from flowing through the attachment hole.

8. A roof assembly for a truck cab, the roof assembly comprising:

a roof shell having an interior surface;

a roof reinforcement structure disposed interiorly of the roof shell and attached to the interior surface of the roof shell, the roof reinforcement structure including

at least one generally U-shaped reinforcement member having opposed bond flanges for attachment to the interior surface of the roof shell;

a channel of the reinforcement member spacing apart the bond flanges and the channel of the reinforcement member forming a condensate drainage path through the

reinforcement member;

an inlet formed through an opening in a bond flange to provide access to the channel; and

an outlet formed in the reinforcement member to be in communication with the channel, the condensate drainage path joining the inlet to the outlet.

9. The roof assembly of Claim 8, wherein the condensate drainage path has an elevation which monotonically decreases from the inlet to the outlet.

10. The roof assembly of Claim 8, wherein at least one character line in the shell forms a corrugation on the roof panel inner surface, the corrugation being downwardly sloped and in fluid communication with at least one channel of a reinforcing member.

11. A method of removing water from a roof assembly comprising the steps of:

directing the water along an interior surface of a roof shell toward a roof reinforcement having a channel for transporting water;

flowing the water into the channel of the roof reinforcement;

flowing the water through the channel; and

draining the water through an outlet in the channel.

12. The method of Claim 11, wherein the step of directing the water along the interior surface of the roof shell further comprises the substep of flowing the water over a water-resistant insulation layer toward the roof reinforcement.

13. The method of Claim 11, further comprising the step of collecting the water from the outlet in a water collection area within the roof assembly.

14. The method of Claim 11, further comprising the step of forming a character line into the inside surface of the roof shell.

15. A roof assembly for a truck cab, the roof assembly comprising: a roof shell having an interior surface and a side panel;

an elongate side reinforcement member having at least one bond flange for attachment to the interior surface of the roof shell;

an interior wall of the side reinforcement member extending upwardly from the at least one bond flange, the elongate side reinforcement member disposed at a substantial angle to vertical such that the interior wall of the elongate side reinforcement member and the interior surface of the side panel act as a condensate collection trough, water condensing on the interior surface of the side panel above the condensate collection trough being collected by the condensate collection trough; and

an outlet disposed such that water collected in the condensate collection trough may drain through the outlet.