Roof assembly and assembly method for a vehicle

Abstract

A roof assembly for a vehicle having an opening in its roof portion, the roof assembly comprising a frame having at least a crossbeam and two substantially parallel longitudinal beams connected to opposite ends of the crossbeam. At least one panel is capable of closing and at least partially opening the opening. A drive system for the panel supports and moves the panel and comprises a drive motor attached to the crossbeam, two substantially parallel guide rails attached to the longitudinal beams, and a support mechanism that is movably guided in the guide rails and operatively connected to the drive motor by an elongated connecting member. The drive system forms a preassembled unit attached to the frame. The frame and the drive system are adapted to each other so that the drive system can be partially inserted into the frame between the longitudinal beams and rotated so that the drive motor is positioned on the lower side of the crossbeam of the frame and the guide rails are at least partially positioned on a portion of the upper side of the longitudinal beam of the frame. A method for assembling the roof assembly is also disclosed.

Description

Technical Field

[0001] The present invention firstly relates to a roof assembly for a vehicle, which has an opening in its roof part, the roof assembly comprising: a frame having at least a crossbeam and two substantially parallel longitudinal beams connected to opposite ends of the crossbeam; at least one closure for closing and at least partially opening the opening; and a drive system for the closure, which supports and moves the closure and comprises a drive motor attached to the crossbeam, two substantially parallel guide rails attached to the longitudinal beams, and a support mechanism movably guided in the guide rails and operatively connected to the drive motor by an elongated connecting member, the drive system forming a preassembled unit attached to the frame. Background Art

[0002] In the roof assembly, the pre-installed drive system is positioned on the upper side of the frame and fastened to it. The crossbeam comprises an opening and the drive motor is attached to the underside of the motor plate so that the drive motor is always accessible from below for maintenance and replacement purposes. Summary of the invention

[0003] One of the objects of the present invention is to improve such a roof assembly.

[0004] To this end, the present invention provides a roof assembly, characterized in that the frame and the drive system are adapted to each other so that the drive system can be partially inserted into the frame between the longitudinal beams and rotated so that the drive motor is positioned on the lower side of the cross beam of the frame and the guide rail is at least partially positioned on a part of the upper side of the longitudinal beam of the frame.

[0005] By arranging the guide rails only at least partially on top of a part of the longitudinal beam of the frame and arranging the drive motor below the cross beam, not only is the drive motor accessible from below, but the drive motor is also automatically positioned in the dry part of the roof assembly, i.e. in a position hidden from dripping water. When the drive motor is located on top of the cross beam as in the prior art, additional measures have to be taken for the water management system to protect the drive motor from dripping water. One possibility is to arrange a drainage channel above the drive motor or to integrate the drainage channel in the front roof to be mounted on the front part of the frame. This can be avoided by the invention. It is also not necessary to provide an opening in the cross beam of the frame to make the motor accessible.

[0006] The drive system is preferably mounted to the frame by mounting members inserted from the upper side of the frame, such as screws inserted from the upper side of the frame and tightened.

[0007] It is particularly advantageous if all mounting operations are carried out on and from the upper side of the frame, thereby preventing the frame from being turned over.

[0008] If the width of the drive system beyond the guide rails at the location of the drive motor is smaller than the width of the drive system at the guide rails, it is easy to insert the drive system between the longitudinal beams and rotate it so that it is positioned under the cross beam.

[0009] If the cross beam has a downwardly depending edge at the side of the cross beam adjacent to the longitudinal beam, this edge may be interrupted to allow the passage of at least a portion of an elongated connecting member, preferably a drive cable or a cable guide thereof.

[0010] Thus, there is no need to thread cables through the upward wall at the transition between the longitudinal and cross beams as required in some prior art roof assemblies.

[0011] In one embodiment, the flanges of the longitudinal beams each have a recess on their edges facing each other to allow vertical passage of the drive system, and wherein the guide rails are located on the upper side of the longitudinal beam on the side of the recess remote from the crossbeam beneath which the drive motor is located.

[0012] This is a way of also allowing a wider drive system to enter the space between the beams and allowing it to rotate into position under the beams.

[0013] In another embodiment, the flanges of the guide rails have recesses in their edges facing away from each other, so that the minimum distance between the recesses of two guide rails is smaller than the minimum distance between the facing edges of two longitudinal beams of the frame.

[0014] This also allows a wider drive system to enter the space between the frame beams, even in a position rotated about the Z axis of the frame. The drive system should be inserted into the space between the beams to a depth such that the recess in the flange of the guide rail is in line with the adjacent part of the longitudinal beam. If the drive system is then rotated about the Z axis, the adjacent part of the longitudinal beam will enter the recess. The adjacent part of the longitudinal beam and / or the guide rail, in particular the horizontal flange, should have a step to enable subsequent rotation about the Y axis.

[0015] The present invention also includes a method for assembling a roof assembly for a vehicle, the roof assembly having an opening in its roof portion, the roof assembly comprising a frame having at least a crossbeam and two substantially parallel longitudinal beams connected to opposite ends of the crossbeam, at least one closure member capable of moving between a closed position closing the opening and an open position, and a drive system (5) for the closure member and supporting and moving the closure member, the drive system comprising a drive motor, two substantially parallel guide rails (12), a support mechanism movably guided in the guide rails and operatively connected to the drive motor by an elongated connecting member, the method comprising the steps of assembling the components of the drive system into a preassembled unit, mounting the preassembled drive system to the crossbeam and longitudinal beams of the frame so that the motor is attached to the crossbeam and the guide rails are attached to the longitudinal beams of the frame.

[0016] The method is characterized in that the drive system is attached to the frame by:

[0017] - moving the drive system at an angle to the frame,

[0018] - moving the drive system partially into the space between the longitudinal beam and the transverse beam, rotating the drive system at least about a transverse rotation axis so that the drive motor is positioned below the transverse beam and the guide rail is at least partially positioned above a portion of the longitudinal beam.

[0019] The drive system can be moved from the upper side of the frame into the space between the longitudinal beams and the cross beams, and wherein the drive motor is first moved into said space, for example by moving the drive system into the space between the longitudinal beams and the cross beams at a position close to the cross beams.

[0020] Alternatively, the drive system can be moved from the underside of the frame into the space between the longitudinal beam and the cross beam, with the end of the guide rail remote from the drive motor being moved into the space first, for example by moving the drive system into the space between the longitudinal beam and the cross beam at a position spaced apart from the cross beam.

[0021] The drive system may be attached to the frame via mounting members manipulated from an upper side of the frame.

[0022] A support mechanism for the panel may be positioned where the panel will be located outside the roof opening, and preferably the panel is attached to the support mechanism immediately before or immediately after the drive system is installed.

[0023] In an advantageous embodiment, with the support mechanism in the position in which the panel is to be in the open position, the drive system moves into the space between the longitudinal beams and the transverse beams.

[0024] This has the advantage that the panel can be mounted to the support mechanism without actuation of the drive system, as typically the panel is mounted to the support mechanism when it is in its open position. Of course, with the support mechanism in its open position, the space between the longitudinal beams should be sufficient to receive the drive system.

[0025] This is even more important in embodiments where the panels are mounted to the support mechanism of the drive system before the drive system is moved into the space between the longitudinal and transverse beams.

[0026] The space must then be sufficient to accommodate not only the drive system but also the panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Further details and advantages of the invention emerge from the following description with reference to the drawings, which show embodiments of the invention by way of example.

[0028] Figure 1 is a perspective view of a vehicle roof with the roof system installed therein.

[0029] Figure 2a and 2b is a perspective plan view of the frame and drive system of the roof system according to the invention in exploded and installed states.

[0030] 3a and 3b are perspective bottom views of the frame and drive system of the roof system according to the invention in exploded and installed states.

[0031] FIG. 3 c shows detail III c from FIG. 3 b at a larger scale.

[0032] Figure 4a and 4b The frame and 3 drive systems are shown in side view and perspective plan view to show the 3 ways of assembling the frame and drive systems.

[0033] Figures 5a and 5b are similar to Figure 4a and 4b , but showing the 3 drive systems in a further introduction position.

[0034] Figure 6a , 6b 6c are enlarged perspective views according to arrows VIa, VIb and VIc in FIG. 5b , showing the adaptation of the frame to realize three assembly modes of the drive system.

[0035] Figure 7 is a plan view of a portion of a frame with an assembled drive system.

[0036] Figure 8a is based on Figure 7The sectional view along section line VIII-VIII in FIG. 1 shows the frame and drive system for realizing the first assembly method.

[0037] Figure 8b is based on Figure 8a Arrow VIIIb Figure 8a Enlarged detail image of .

[0038] Figure 9a and 9b is similar to Figure 8a and 8b , but showing the frame and drive system for implementing the second assembly method.

[0039] Fig.10a and 10b is similar to Figure 8a and 8b , but showing the frame and drive system for implementing the third assembly method.

[0040] 11a, 11b and 11c are a side view, a plan view and a perspective view of the frame and the drive system for implementing the fourth assembly method in the first assembly step.

[0041] Figures 12a, 12b and 12c are views similar to Figures 11a, 11b and 11c, but showing a second assembly step.

[0042] Figures 13a, 13b and 13c are views similar to Figures 11a, 11b and 11c, but showing a third assembly step.

[0043] Fig.14a and 14b An exploded view from below and a larger bottom view of the frame with reinforced corner parts are shown.

[0044] Fig.15a and 15b is a longitudinal section and a front view of a frame and a drive system showing the individual fasteners used to assemble the drive system and the frame in a first assembly option.

[0045] Fig.16a and 16b is similar to Fig.15a and 15b , but showing a second assembly option.

[0046] Fig.17 This is an exploded view of the frame and front header. DETAILED DESCRIPTION

[0047] Figure 11 shows a portion of a vehicle, in particular a roof of a car, which comprises at least one roof opening 1 defined in a (fixed) roof part 2. A closure element, here in the form of a closure panel 3, can be moved in a closed position (not shown) and in an open position ( Figure 1 ), in which the closure element closes the roof opening 1, and in which the closure element opens the roof opening 1, and in which the closure element is at least partially positioned above the roof part 2, where the fixed roof part adjoins the rear edge of the roof opening 1.

[0048] As is known per se, such a roof system, which is also referred to as a spoiler roof or an external sliding roof, may comprise additional elements, such as a tiltable wind deflector positioned in front of the roof opening 1, or a further movable or fixed panel, which is located, for example, behind the panel 3 when the panel 3 is in its closed position.

[0049] 2 and 3 show the main components of the roof assembly, including a frame 4, a drive system 5 for the panels 3 and a roof cover 6 covering the front side of the frame 4 and forming part of the roof skin after the roof assembly is installed.

[0050] The frame 4 comprises two parallel side beams or longitudinal beams 7 and two transverse beams, namely a front beam 8 and a rear beam 9 connected at their front and rear ends to the longitudinal beams 7. The frame 4 may be formed in one piece or from a plurality of parts mounted together and made of, for example, metal or plastic material.

[0051] The drive system 5 for the panel 3 comprises at least one or more drive motors 10 (here two drive motors 10), an elongated transmission member (e.g. a push-pull cable 11), two parallel guide rails 12 to be mounted to the longitudinal beam 7, and an operating or supporting mechanism 13 for closing the panel 3 so as to move it between a closed position and an open position. For this purpose, a portion of the supporting mechanism 13 can slide in each guide rail 12. The panel 3 comprises, for example, a transparent or metal opaque sheet of glass or plastic, which is supported on the longitudinal side by a panel support that is fixed to the sheet of the panel 3, for example, via an encapsulating material and / or any other device. The guide rail 12 is straight or slightly curved so as to follow the curvature of the roof. Such a guide rail and supporting mechanism are shown, for example, in US9,969,246, the contents of which are incorporated herein by reference. The supporting mechanism 13 comprises a front support 14 and a rear support 15, the front support 14 supporting and moving the front side of the panel 3, and the rear support 15 supporting and moving the rear side of the panel 3 at the position of each guide rail 12. When a guide rail 12 is used in the context of the present invention, it also includes a flange or component attached to it or supporting it and forming part of the drive system 5.

[0052] The drive system 5 can be preassembled into a U-shaped preassembled assembly, which includes a cable 11 and a guide rail 12, and a drive motor 10 mounted on a front member 16. The cable 11 can be guided in a cable guide 17, which can also be used to connect the guide rail 12 to the front member 16 to form a U-shaped drive system.

[0053] 2 and 3 , the drive system 5 is mounted to the frame 4 so that the front member 16 with the motor 10 and the cable 11 / cable guide 17 is positioned below the front beam 8 of the frame 4, while the guide rails 12 are at least partially positioned above the longitudinal beams 7. Of course, the guide grooves of the guide rails 12 will always be uncovered by the frame 4, at least in the position in which the front support 14 and the rear support 15 of the support mechanism 13 move in these guide grooves of the guide rails 12.

[0054] Figures 4 and 5 show three ways of mounting the drive system 5 to the frame 4. The main difference between these ways in these embodiments is the position and the way in which the drive system 5 is inserted into the space between the longitudinal beam 7 and the cross beams 8,9.

[0055] The drive system 5' is inserted into this space near the front beam 8, with the motor 10 inserted first, so that the horizontal flange 18 of the guide rail 12 will gradually rest on top of the horizontal flange 19 of the frame 4. The front member 16 with the motor 10 and most of the cable guide 17 will be located below the front beam 8. A recess or interruption 20 ( Figure 6a ), in order to facilitate the insertion of the drive system 4 during assembly and to allow, after assembly, the passage of the guide channel 17 for the drive cable 11 from a position above the flange 19 of the longitudinal beam 7 of the frame 4 to a position below the front beam 8. Thus, it is not necessary to pass the cable 11 through a portion of the frame 4. Since the width of the drive system 4 beyond the guide rail 12 at the location of the cable guide 17 is smaller than at the location of the guide rail 12, it is not necessary to make a recess of the frame 4 or to adapt the flange 19 to allow the insertion of the drive system 5.

[0056] The drive system 5" should be inserted into the space approximately in the middle between the front beam 8 and the rear beam 9. A recess 21 ( Figure 6b ). The depth of the recess 21 is such that the width of the drive system 5 at the location of the guide rail 12 is slightly smaller than the distance between the bottoms of the recesses 21 in the opposing flanges 19 to allow insertion of the drive system 5. The horizontal flange 18 of the guide rail 12 will be positioned on top of the horizontal flange 19 of the frame 4 towards the rear beam 9 and will be positioned below the horizontal flange 19 of the frame 4 towards the front beam 8.

[0057] The drive system 5'' is inserted from below into the space between the beams 7, 8, 9 (thus inserting first the end of the guide rail 12 remote from the motor 10) in order to minimize the insertion depth. Only a small part of the horizontal flange 18 of the guide rail 12 will be above the horizontal flange 19 of the frame 4, and most of it will be below. The recess 22 ( Figure 6c ) to determine the insertion position.

[0058] From the insertion position shown in FIGS. 5 a and 5 b , the drive systems 5 ′, 5 ″ and 5 ′″ are rotated according to arrow A so as to unite the drive system 5 and the frame 4 so that the flanges 18 and 19 are positioned one on top of the other.

[0059] The height of the flanges 18 and / or 19 is such that a portion of the flange 18 may be located below the flange 19 , while another portion thereof may be located above the flange 19 . Figure 7 The drive system 5 and the frame 4 are shown in an assembled state. Figure 8a and 8b An embodiment comprising a drive system 5 ′ is shown in which the horizontal flange 18 of the guide rail 12 is completely located above the flange 19 of the frame 4 . Figure 9a and 9b A variation with a drive system 5" is shown and it clearly shows that the flange 19 of the frame 4 has a higher front portion 19a and a lower rear portion 19b to allow the flange 18 to be located below and above it. Fig.10a and 10b Something similar is shown with a drive system 5'" having a longer portion 19a and a shorter portion 19b.

[0060] Figures 11, 12 and 13 show another way of inserting the drive system 5"" into the space between the beams 7, 8 and 9. In this case, instead of the flange 19 of the frame 4 having a recess, the flange 18 of the drive system 5"" has a recess 23 for positioning the drive system 5". The drive system 5"" is inserted into the space in a vertical position, but rotated about the vertical (Z) axis so that the guide rails 12 are close to the corners between the beams 7, 8 and beams 7, 9, respectively. The drive system 5"" is moved into the space so that the recess 23 is located at the height of the horizontal flange 19 of the frame 4. The drive system 5"" can then be rotated about the vertical axis to a position parallel to the beams 8, 9 and then about the horizontal transverse axis (Y) to a position in which the flanges 18 and 19 are parallel. In this case, the distance between the flanges 19 of the frame 4 is greater than the distance between the bottoms of the recesses 23 in the flanges 18 of the guide rails 12. Likewise, the flanges 18 and / or 19 must be adapted to allow the below / above position.

[0061] Fig.14a and 14b The frame 4 and the drive system 5 are shown in the assembled state. Fig.14a Additional reinforcement corner members 24, 25 are shown, which are mounted on Fig.14b These reinforcing corner parts 24, 25 are used to restore or increase the strength / rigidity of the frame 4 (e.g. due to the removal of material of the frame 4) to allow a specific assembly of the drive system 5 and the frame 4. For example, in order to allow the passage of the cable guide 17, the downwardly depending flange or edge 29 of the cross beams 8 and / or 9 may be interrupted by a recess or interruption 20, which reduces the rigidity of these beams 8, 9. However, it is noted that this way of mounting the drive system 5 in the frame 4 hardly reduces the strength of the frame 4 in the vicinity of the rear beam 9.

[0062] Figures 15 and 16 show two embodiments for fastening the drive system 5 to the frame 4. In the embodiment of Figure 15, all screws 26 fastening the flange 18 of the drive system 5 to the flange 19 of the frame 4 are inserted and tightened from above, and the screws 27 fastening the front member 16 of the drive system 5 to the front beam 8 are also inserted and tightened from above. The screws 28 fastening the drive motor 10 to the front member 16 are always inserted and tightened from below to ensure the possibility of maintenance from below.

[0063] The latter is therefore also the case in the embodiment of FIG. 16 , in which the screws 26 and 27 are also inserted and tightened from below.

[0064] Fig.17 The steps of mounting the top cover 6 to the front beam 8 are shown. In the case that the top cover 6 should be mounted to the front beam 8 when the screws 27 are inserted as shown in FIG. 15 , the top cover 6 can only be mounted after the screws 27 have been inserted and tightened. In the case according to FIG. 16 , in the case that the screws 27 are inserted from below, the top cover 6 can be mounted before or after the screws 27 are in place. The top cover 6 can be glued to the front beam 8, but other mounting means can also be used, preferably so that no mounting means are visible on the top side of the top cover 6.

[0065] In the drawings, the front and rear supports 14, 15 of the drive system 5 are shown in a position in which the panel 3 is to be closed. However, the adjustable supports 14, 15 can be positioned in a position to open the panel 3. In an embodiment where the panel screws are hidden behind the guide wall with the panel 3 in its closed position, this allows the panel 3 to be installed immediately after the drive system 5 is installed, because the panel 3 is always installed in its open position.

[0066] The invention is not limited to the embodiments shown in the drawings and described above, which may be varied in different ways within the scope defined by the appended claims. Aspects of the various embodiments may be used in other combinations. The drive system may be such that one or more drive motors are mounted on a rear member (to be) positioned below the rear beam of the frame. The frame may also have more than two cross beams.

Claims

1. A roof assembly for a vehicle, the roof assembly having an opening (1) in a roof portion (2) thereof, the roof assembly comprising: a frame (4) having at least a cross beam (8, 9) and two substantially parallel longitudinal beams (7) connected to opposite ends of the cross beam; at least one closure element (3) for closing and at least partially opening the opening (1); as well as A drive system (5) for the closure, the drive system supporting and moving the closure and comprising: a drive motor (10) attached to the crossbeam; two substantially parallel rails (12) attached to the longitudinal beam (7); and a support mechanism (13) which is movably guided in the guide rail and is operatively connected to the drive motor via an elongated connecting member (11), The drive system forms a preassembled unit attached to the frame, Characterized in that the frame (4) and the drive system (5) are adapted to each other so that the drive system can be partially inserted into the frame between the longitudinal beams (7) and rotated so that the drive motor (10) is positioned on the lower side of the cross beams (8, 9) of the frame and the guide rail (12) is at least partially positioned on a part of the upper side of the longitudinal beams (7) of the frame (4).

2. The roof assembly according to claim 1, wherein: The drive system (5) is mounted to the frame (4) via mounting members (26, 27) inserted from the upper side of the frame.

3. The roof assembly according to claim 2, wherein: The mounting members (26, 27) are screws that are inserted from the upper side of the frame (4) and tightened.

4. The roof assembly according to claim 1, wherein: The width of the drive system (5) beyond the guide rail (12) at the location of the drive motor (10) is smaller than the width of the drive system at the guide rail.

5. The roof assembly according to claim 4, wherein: The cross beam (8) has a downwardly depending edge (29) at the side of the cross beam adjacent to the longitudinal beam (7), and the edge is interrupted by a discontinuity (20) to allow at least a part of the elongated connecting member (11) of the drive system (5') to pass through.

6. The roof assembly according to claim 1, wherein: The longitudinal beams (7) each have a recess (21) on their edges facing each other to allow the vertical passage of the drive system (5"), and wherein, on the side of the recess (21) remote from the cross beam (8) below which the drive motor (10) is positioned, the flange (18) of the guide rail (12) is located on the upper side of the flange (19) of the longitudinal beam (7).

7. The roof assembly according to claim 1, wherein: The flanges (18) of the guide rails (12) of the drive system (5") have recesses (23) in their edges facing away from each other, so that the minimum distance between the recesses of the two guide rails is smaller than the minimum distance between the facing edges of the two longitudinal beams (7) of the frame (4).

8. A method of assembling a roof assembly for a vehicle, the roof assembly having an opening (1) in a roof portion (2), the roof assembly comprising: a frame (4) having at least a cross beam (8, 9) and two substantially parallel longitudinal beams (7) connected to opposite ends of the cross beam; at least one closure member (3) movable between a closed position closing the opening (1) and an open position; as well as A drive system (5) for the closure (3) and supporting and moving the closure, the drive system comprising a drive motor (10), two substantially parallel guide rails (12) and a support mechanism (13) which is movably guided in the guide rails and operatively connected to the drive motor via an elongated connecting member (11), the method comprising the following steps: - assembling the components of the drive system (5) into a preassembled unit, - mounting the preassembled drive system to the cross beams (8, 9) and longitudinal beams (7) of the frame (4) such that the motor (10) is attached to the cross beams (8, 9) and the guide rails (12) are attached to the longitudinal beams (7) of the frame, Characterized in that the drive system (5) is attached to the frame (4) by: - moving the drive system (5) at an angle to the frame (4), - Partially moving the drive system (5) into the space between the longitudinal beam (7) and the cross beams (8, 9), rotating the drive system at least around the transverse rotation axis (Y) so that the drive motor (10) is positioned below the cross beam (8) and the guide rail (12) is at least partially positioned above a portion of the longitudinal beam (7).

9. The method according to claim 8, wherein: The drive system (5', 5", 5"") moves from the upper side of the frame (4) into the space between the longitudinal beams (7) and the transverse beams (8, 9), wherein the drive motor (10) moves into the space first.

10. The method according to claim 9, wherein: The drive system (5') moves into the space between the longitudinal beam (7) and the transverse beams (8, 9) at a position close to the transverse beam (8).

11. The method according to claim 8, wherein: The drive system (5'") moves from the lower side of the frame (4) into the space between the longitudinal beam (7) and the cross beams (8, 9), wherein the end of the guide rail (12) remote from the drive motor (10) moves into the space first.

12. The method according to claim 11, wherein: The drive system (5'") moves into the space between the longitudinal beam (7) and the transverse beams (8, 9) at a position spaced apart from the transverse beam (8).

13. The method according to claim 8, wherein: The drive system (5) is attached to the frame (4) by mounting members (26, 27) manipulated from the upper side of the frame.

14. The method according to claim 8, wherein: When the support mechanism (13) is in the open position of the closure (3), the drive system (5) moves into the space between the longitudinal beam (7) and the transverse beams (8, 9).

15. The method according to claim 8, wherein: The closing element (3) is mounted to the support mechanism (13) of the drive system (5) before the closing element is moved into the space between the longitudinal beam (7) and the transverse beam (8, 9).

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