Inalfa Roof Systems
Inalfa Roof Systems is a world leader in sun roofs and roof systems for cars and trucks. Although the volumes are smaller than other automotive sectors, the requirements in terms of quality, reliability and safety are the same or even higher. Inalfa also supplies roof systems for cars at the top end of the market which need to provide a high level of comfort and low wind noise.
A new type of sliding and tilting roof required the development of a bellows-type side cover for the gap between the fixed part of the car roof and the tilting section. As the new roof had compound curves the extrusions previously used were unsuitable. The required geometry of the cover is now obtained by injection moulding. This part is made of a TPE (thermoplastic elastomer) which has properties similar to rubber. To reduce costs, the snap-fit fixings to the moving part of the roof are integrated into the cover. These elements are made of PP, a rigid polymer, using a 2-component injection moulding process.
This development process had three key outcomes:
- A cover with an appearance suited to the top end of the market.
- The integrated snap-fit fixings significantly reduce the assembly time.
- With a limited tooling modification the same covers can be used for other types of roofs
