Locking system with toggle lever mechanism for easy and quick operation, one-handed and without the use of additional tools, to secure the front scissor mechanism of pop-up vehicle roofs and roof tents in the end position.

Abstract

Locking system for securing a pop-up vehicle roof or roof tent with crossed lever or scissor mechanism, in particular an electro-hydraulic pop-up roof of vehicles of the Volkswagen T5, T6, T6.1 and T7 series, characterized in that the locking system can be inserted into the front scissor mechanism and creates a mechanical locking state in the raised end position of the roof, wherein a toggle lever mechanism in a locked over-center position fixes the scissor mechanism by positive and / or non-positive locking, so that an unintentional lowering of the roof is prevented regardless of the drive or control system.

Description

Technical field

[0001] The invention relates to vehicle technology, in particular a mechanical locking device for locking pop-up roofs (electro-hydraulically or manually operated) with crossed levers / scissor mechanisms in the raised end position. Preferred applications are pop-up roofs of camping and recreational vehicles, especially vehicles of the Volkswagen T5, T6, T6.1 and T7 series, as well as roof tents with scissor mechanisms. State of the art

[0002] Pop-up roofs with scissor mechanisms are often electro-hydraulically operated, with the hydraulic system holding the roof in the raised position. In practice, malfunctions occur, including: • Pressure loss / leaks in the hydraulic system • Mechanical wear and play in the scissor mechanism • Failures of the electrical control or power supply

[0003] Such malfunctions can cause the roof to lower uncontrollably, posing safety risks to occupants and potentially damaging the vehicle and its interior. Mechanical locking mechanisms, independent of the drive system, specifically designed for the front scissor mechanism of near-production pop-up roofs, are either not readily available on the market or are not tailored to the specific kinematics (geometry, installation space, operating forces) of the aforementioned vehicle series. Existing solutions sometimes require structural modifications, tools, or lack redundant safety features. The problem underlying the invention

[0004] The aim is to provide an easily retrofittable, drive and energy system independent, ergonomically operable and tolerance-insensitive locking mechanism that mechanically blocks the front scissor mechanism in the extended end position, prevents unintentional lowering and can be used without structural modifications to the vehicle. Description of the invention

[0005] The problem is solved by a locking system that can be inserted into the front scissor mechanism of the pop-up roof and creates a mechanical blocking state in the end position. At its core is a toggle lever mechanism that, in a locking position extending beyond the dead center, secures the scissor mechanism by positive and / or non-positive locking. This ensures that the locking mechanism remains effective even in the event of pressure loss, control failure, or power loss.

[0006] The locking system is designed as a one-piece or pre-assembled retrofit component that can be inserted and removed without tools and with one hand while the scissor arms are open. An adapter / lever arm adapted to the geometry of the scissor arms ensures a positive locking engagement. Length-adjustable segments can be provided to accommodate differences between product series and tolerances. An optional additional safety device (e.g., a locking pin) prevents unintentional release. Advantages of the invention • Safety: Redundant mechanical locking mechanism independent of hydraulics / electrics; prevents lowering into the end position. • Retrofit capability: Installation without vehicle modification; suitable for existing vehicles. • Ergonomics: One-handed, intuitive operation with low actuation forces thanks to over-dead-point knee levers. • Manufacturing and cost advantages: use of standard parts, CNC milled parts, 3D printed components with metallic inserts; low manufacturing costs. • Robustness: Low wear due to material and coating; self-locking effect under dynamic vehicle load. • Adaptability: Length / geometry adjustment covers tolerances and variants; transferable to roof tents and other scissor mechanisms. Brief description of the drawings

[0007] Note: The drawings are for illustrative purposes only. Typical representations include: • Fig. 1: Side view of the locking system (overview of individual parts AE) • Fig. 2: Top view of the locking system • Fig. 3: Isometric view of the locking system • Fig. 4: Isometric sectional view of the locking system (overview of individual parts FG) • Fig. 5: Locking system installed in front roof mechanism Detailed description of at least one embodiment

[0008] In a preferred embodiment, the locking system comprises: • a toggle clamp (B) as the basic element of the toggle mechanism; • a CNC-milled aluminum adapter / lever arm part (C) that is adapted to the geometry of the front scissor mechanism and ensures a positive engagement; • a length-adjustable segment (D) (e.g. by means of threaded / slotted guide) to compensate for series and tolerance differences (T5, T6, T6.1, T7) and to optimize operating forces; • a base slide (A) made from an aluminum profile system (e.g. 30×30×3 mm) • Standard fasteners (F) (e.g. M8 screws) for assembly; • a hook element (E) made of high-strength plastic (e.g. ASA) with metallic reinforcement (F) (e.g. inserted stainless steel angle) that supports the engagement with the scissor arms; • Surface-friendly, friction-reducing coatings (e.g. powder coating) on ​​aluminium parts to protect adjacent vehicle surfaces. Function and handling:

[0009] To lock the component, with the scissor mechanism open, it is positioned at defined points of engagement on the front scissor and actuated using a toggle lever. The toggle lever moves in a controlled manner past its dead center into a self-locking position. An optional additional safety device (locking pin) can be inserted into a designated hole to prevent unintentional opening. To release, the additional safety device is removed and the toggle lever is returned to its locked position; the component can then be removed without altering the vehicle's mechanics. Materials and manufacturing:

[0010] Main metallic components (e.g., aluminum) are preferably machined and powder-coated. Plastic components can be manufactured using rapid prototyping / 3D printing and reinforced with metallic inserts. The assembly utilizes standard and profile system components to reduce costs and facilitate spare parts supply. The design is engineered to withstand the loads encountered during operation of the scissor mechanism. Scope:

[0011] The system is specifically designed as a retrofit kit for vehicles with pop-up roofs in the VW T5, T6, T6.1, and T7 series. It can be adapted to other vehicle types and roof tents with a comparable front scissor mechanism, provided the adapter part is geometrically modified.

[0012] Design variants: • Alternative toggle lever units (design / size) for adjusting operating forces. • Varying shape elements of the adapter contour for different scissor arm profiles. • Additional detent / stop elements for defined end position limitation of the over-center travel. • Material alternatives (high-strength plastic with fiber reinforcement) for weight savings. Reference symbol list (example; adapt to drawings) 1 pop-up roof ( Fig. 5) 2 Front scissor mechanism ( Fig. 5) 3 Scissor arm left ( Fig. 5) 4 Scissor arm right 5 toggle clamps (B) 6 Lever arm / adapter part (CNC) (C) 7 Length-adjustable segment (D) 8 Base slide (profile) (A) 9 Pipe element (D) 10 hook element (plastic) with 10a metal reinforcement (E) 11 Safety / locking pin 12 Lifting / Locking Devices 13 fastening / standard elements (F,G)

Claims

[1] Locking system for securing a pop-up vehicle roof or roof tent with crossed lever or scissor mechanism, in particular an electro-hydraulic pop-up roof of vehicles of the Volkswagen T5, T6, T6.1 and T7 series, characterized by , that the locking system can be inserted into the front scissor mechanism and creates a mechanical blocking state in the raised end position of the roof, wherein a toggle lever mechanism in a locked over-center position secures the scissor mechanism by positive and / or force locking, so that an unintentional lowering of the roof is prevented regardless of the drive or control system. [2] Locking system according to claim 1, characterized by , that the toggle lever mechanism includes a toggle lever clamp which can be coupled via a connecting part adapted to the scissor mechanism. [3] Locking system according to any of the preceding claims, characterized by, that a CNC-manufactured adapter or lever arm part has a contour adapted to the geometry of the front scissor mechanism in order to create a positive engagement. [4] Locking system according to any of the preceding claims, characterized by , that an extension or adjustment segment of the lever arm is adjustable in length to compensate for tolerances, series differences or variants of the vehicle and roof tent. [5] Locking system according to any of the preceding claims, characterized by , that the system is designed as a one-piece or pre-assembled retrofit component that can be inserted into and removed from the open scissor mechanism with one hand and without tools. [6] Locking system according to any of the preceding claims, characterized by , that the toggle lever mechanism in the locked state creates a clamping and / or locking and / or positive locking without the need to actuate a screw connection. [7] Locking system according to any of the preceding claims, characterized by , that an additional safety device in the form of a locking or securing pin is provided, which redundantly secures the locked state against unintentional release. [8] Locking system according to any of the preceding claims, characterized by that the system operates independently of the electro-hydraulic drive and its energy supply and maintains the locking of the end position in the event of drive failure or pressure loss. [9] Locking system according to any of the preceding claims, characterized by , that it is designed as a retrofit kit for vehicles with a pop-up roof, especially the Volkswagen T5, T6, T6.1 and T7 series, without requiring any structural changes to the body or scissor mechanism. [10] Locking system according to any of the preceding claims, characterized bythat the operating forces are ergonomically designed to allow one-handed operation and secure locking even by people of shorter stature. [11] Locking system according to any of the preceding claims, characterized by that the components consist of metal and / or high-strength plastic, in particular a CNC-milled lever arm made of aluminum, a base slide made of an aluminum profile system, a tube element and standard connecting elements, optionally with friction-reducing, paint- and surface-protecting coatings, in particular powder coatings. [12] Locking system according to any of the preceding claims, characterized by , that a hook element made of plastic with metallic reinforcement, in particular a 3D-printed component with an inserted stainless steel angle, supports the engagement in the scissor mechanism. [13] Locking system according to any of the preceding claims, characterized by, that manufacturing variants are provided through machining, bending and material forming, rapid prototyping / 3D printing with metallic inserts as well as assembly from profile systems and standard parts. [14] Locking system according to any of the preceding claims, characterized by , that the positive locking engagement is designed in such a way that a self-locking locking effect is maintained in the end position under dynamic load of the scissor mechanism during vehicle operation. [15] Locking system according to any of the preceding claims, characterized by that the toggle lever mechanism has a defined over-dead point locking travel which is reproducibly limited by stop and / or detent means to prevent incorrect operation.

Images