Semi-rigid vehicle cover

Abstract

A semi-rigid cover comprising a layered arrangement. The layered arrangement includes a first layer comprised of a structural polymer, a second layer comprised of a fabric, and a third layer comprised of a foam.

Description

SEMI-RIGID VEHICLE COVERCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Application No. 63 / 546,659, filed October 31, 2023 and incorporated herein by reference in its entirety.FIELD

[0002] The present teachings generally relate to a semi-rigid vehicle cover.BACKGROUND

[0003] Removable body panels (e.g., roofs, doors, etc.) are provided in some sports utility vehicle models (e.g., Jeep, Bronco, etc.). The removable body panels provide consumers with a customizable driving experience, whether for road driving or oflf-roading. Commonly, sports utility’ vehicles are provided with removable covers for vehicle roofs, which allows consumers tire ability to experience open-air driving.

[0004] Removable roof covers are typically available in two varieties, soft covers and hard covers. Soft covers are typically fabricated from single, flexible layers of material (e.g., vinyl fabric). Hard covers are typically fabricated from a rigid polymer (e.g., a fiber-reinforced thermoset polymer). These different constructions come with their own benefits and challenges.

[0005] Storage is one concern with cover material selection. Soft covers tend to take up less storage space by virtue of their weight, foldability, rollability, etc. Hard covers typically comprise larger segments (e.g., segments adapted to cover rear passenger and / or cargo spaces) that occupy larger volumes of storage space.

[0006] Various installation challenges may be realized with both varieties of covers. Soft covers typically require more steps, hardware, connections, and individual cover segments, but may be easier to handle for a single person performing the installation due to their size and weight. Hard covers comprise comparatively fewer segments that can be positioned and bolted / latched to existing vehicle structures with comparatively fewer steps, hardware, and connections, but can be heavy and cumbersome to work with, often requiring more than one person to install.

[0007] Material selection carries other implications as well. The thin fabrics of soft covers provide little thermal insulation, acoustic insulation, and theft protection. Moreover, noise can be generated from flapping of the fabric with the vehicle at speed. The comparatively thicker and more rigid materials of hard covers provide for the thermal insulation, acoustic insulation, theft protection, and noise mitigation that soft covers tend to lack. Additionally, soft covers typically accommodate flexible windows (e.g., vinyl windows), which can be susceptible to scratching or other damage that diminishes the clarity thereof while hard coverscan be adapted for glass or other forms of rigid windows that arc comparatively more damage-resistant. UV and chemical resistance are other considerations of material selection.

[0008] Moreover, owing to materials and fabrication methods, soft covers tend to be less expensive relative to hard covers.

[0009] There is a need for a removable body panel (e.g., roof cover) that combines the benefits of conventional soft body panels and hard body panels.

[0010] There is a need for a removable body panel (e.g., roof cover) that can be stored without occupying large amounts of space.

[0010] There is a need for a removable body panel (e.g.. roof cover) that is lightweight to aid in installation and removal, while requiring less steps, hardware, and / or connections relative to conventional soft body panels.

[0011] There is a need for a removable body panel (e.g., roof cover) that provides acoustic insulation, thermal insulation, noise mitigation, theft resistance, UV resistance, chemical resistance, or any combination thereof.

[0012] There is a need for a removable body panel (e.g., roof cover) that can be adapted to accommodate damage-resistant window materials.

[0013] There is a need for a removable body panel (e.g., roof cover) that provides at least some of the benefits of conventional hard body panels discussed above while being comparatively less expensive.SUMMARY

[0014] The present teachings provide for a semi-rigid cover, which may address at least some of the needs identified above.

[0015] The semi-rigid cover may comprise a first layer adapted to orient away from a cabin interior of the vehicle, a second layer adapted to orient toward the cabin interior of the vehicle, and a third layer located between the first and second layers. The first layer may comprise a structural polymer. The second layer may comprise a fabric. The third layer may comprise a foam.

[0016] The structural polymer may be a thermoplastic polyolefin. The fabric may be a non-woven fabric. The foam may be a polypropylene foam.

[0017] The semi-rigid cover may at least forms a roof of the vehicle.

[0018] The semi-rigid cover comprise a plurality of panels. The plurality of panels may include one or more of a first panel adapted to cover a top of the vehicle, a second panel and / or a third panel adapted to cover, respectively, a passenger side and a driver side of the vehicle, and a fourth panel adapted to cover a rear of the vehicle.

[0019] One or more of the plurality of panels may include a window.

[0020] The window may be removable or can be manipulated into an open position and a closed position. The window may slide between the open and closed positions or hingedly rotates between the open and closed positions.

[0021] One or more of the plurality of panels may include one or more tracks for receiving the window. The window' may slide into, out of, and / or within the one or more tracks.

[0022] Tire window may be fastened to the plurality of panels by stitching, heat welding, a chemical adhesive, or any combination thereof.

[0023] The plurality of panels may comprise fasteners for fastening the plurality of panels to each other. The fasteners may bolts, zippers, snaps, channels / tracks and inserts, hook-and-loop fasteners, snap-fit buckles, bolts, latches (e.g., draw latches, pivoting latches (e.g., L-shaped pivoting latches), or both), guide pins, or any combination thereof.

[0024] Tire plurality of panels may comprise fasteners and / or holes for accepting fasteners for fastening the plurality of panels to tire vehicle.

[0025] At least tw o of the plurality of panels may be continuous with each other.

[0026] The first panel may include two, three, or even four discrete segments that are fastenable to each other. The discrete segments may generally locate over a front driver seat, a front passenger seat, a rear left passenger seat, a rear right passenger seat, or any combination thereof.

[0027] One or more of tire plurality of panels may comprise a structural support. Tire structural support may be arranged around tire w indow, along one or more comers or radii of the plurality of panels, along one or more edges of the plurality of panels, or any combination thereof. The structural support may include a wire, a tube, a generally planar member, or any combination thereof. The structural support may be located betw een two of the layers described herein.

[0028] The first, second, and / or third layers may be compression molded to form a profile of the vehicle.

[0029] One or more of the plurality of panels may comprise one or more flaps. Tire one or more flaps may fold over an interface betw een adjacent panels.BRIEF DESCRIPTION OF THE DRAWING

[0030] FIG. 1A and FIG. IB illustrate a semi-rigid cover according to the present teachings installed on a vehicle.

[0031] FIG. 2 is a perspective view of a semi-rigid cover according to the present teachings.

[0032] FIG. 3 is a sectional view of a semi-rigid cover according to the present teachings.DESCRIPTION

[0033] The present teachings describe a semi-rigid vehicle cover. Hie semi-rigid vehicle cover may function as a roof, one or more pillars, one or more windows, one or more hatches (e.g., a rear hatch), or any combination thereof. Although, the present teachings contemplate that the materials and configurations described herein may be adapted for other vehicle components, such as doors.

[0034] The semi-rigid vehicle cover described herein may find benefit with its lightweight construction, particularly with cost, ease of installation, and storage. In this regard, the present teachings provide for a layered construction that may combine favorable properties from different types of materials into a single article. The layered construction may provide for structural rigidity, acoustic insulation, thermal insulation, water resistance, UV resistance, chemical resistance, or any combination thereof.

[0035] The semi-rigid vehicle cover described herein may bridge the gap betw een conventional soft covers and conventional rigid covers in terms of functionality, weight, cost, or any combination thereof.

[0036] The semi-rigid vehicle cover may comprise one or more of a first layer, a second layer, and a third layer. The first layer may be fabricated from a structural polymer (e.g., thermoplastic polyolefin (“TPO")). The second layer may be fabricated from a fabric. The fabric may include a woven or a non-woven fabric. The third layer may be fabricated from a foam (e.g., a polypropylene foam).

[0037] The first layer may be adapted to orient away from a cabin interior of the vehicle. The second layer may be adapted to orient tow ard a cabin interior of the vehicle. The third layer may be located between the first and second layers.

[0038] The present teachings contemplate a first and third layer both comprised of a fabric. Uris arrangement may provide for a semi-rigid vehicle cover that is overall lighter. The thickness of the first and third layers may be generally greater as compared to an arrangement of a fabric layer with a structural polymer layer. Thus, tire greater thickness may provide rigidity where the structural polymer is absent. The fabric adapted to located on an exterior of the vehicle may be weatherproofed, such as by a w aterproof coating.

[0039] The layered structure may cooperate to provide structural, thermal insulation, and / or acoustic insulation properties to the semi-rigid cover. The structural polymer may primarily function to provide structure to the semi-rigid cover. The structural polymer may have sufficient rigidity to prevent flapping when the vehicle is at speed. This may be understood in contrast to conventional soft covers, which may flap at speed and produce noise. The foam may provide thennal and / or acoustic insultation properties, structure to the semi-rigid cover, or both. The fabric may provide a soft surface, aesthetically pleasing surface, or both to the interior of the cabin. The fabric may also contribute to thermal insulation, acoustic insulation, or both.

[0040] The panels may comprise one or more structural supports. The structural supports may function to structurally reinforce the panels, particularly in areas where windows may be present, where comers and / or radii may be present, where edges may be present, or any combination thereof. The structural supports may comprise a wire, a tube, a generally planar member (e.g., a rigid plate), or any combination thereof.

[0041] The structural supports may be located between one or more of the layers. The structural supports may be located, at least partially, on an exposed surface of the semi-rigid vehicle cover. The structural supports may wrap around and be located on two opposing exposed surface of the semi-rigid vehicle cover.

[0042] The one or more of the aforementioned layers may be thermoformed. The thennofonning may define the comers, curvature, aerodynamic features, fluid guiding features, or any combination thereof, of the semi-rigid cover such that the profile of the vehicle may be replicated by the semi-rigid cover. The comers, curvature, etc. may be complementary with the frame of the vehicle.

[0043] Thermoforming may define guide pins, as described herein. The guide pins may be formed by the stmctural polymer. Tire guide pins may extend through the foam and fabric layers. Tire guide pins may locate into adjacent panels, adjacent segments, the vehicle, or any combination thereof.

[0044] The semi-rigid cover may comprise a plurality of panels. The plurality of panels may include a first panel adapted to cover a top of the vehicle; a second panel and / or third panel adapted to cover, respectively, a passenger side and a driver side of the vehicle; a fourth panel adapted to cover a rear of the vehicle; or any combination thereof. The semi-rigid cover may at least cover and / or form a roof (top) of the vehicle.

[0045] Parting lines may be located between the plurality of panels. For example, a parting line may be located between a first panel, second panel, third panel, fourth panel, or any combination thereof. The parting lines may define a separation between the plurality of panels, a hinge (e.g.. a living hinge), or both.

[0046] One or more of the plurality of panels may comprise one or more lips. The lips may function to extend, across parting lines, over or underneath adjacent panels.

[0047] One or more of the plurality of panels may comprise one or more offsets. The offsets may function to provide an engagement surface for tire one or more lips, provide an engagement surface for one or more doors, provide a generally flush surface between panels and / or doors, or any combination thereof. For example, an offset may drop below an exterior surface of a first panel by generally the same thickness as a lip on a second panel, and in this regard, the lip may rest upon the offset and thus provide for a generally flush outer surface. It is understood that a lip may comprise an offset.

[0048] One or more weatherproofing members may be disposed upon the one or more lips and / or offsets. The weatherproofing members may include gaskets, seals, tire like, or any combination thereof. Tire seals may be elastomeric. The seals may be foamed. Hie weatherproofing may prevent water intrusion, debris intrusion, and air intrusion.

[0049] The plurality of panels may include two or more, three or more, or even four or more discrete segments. A parting line may be located between the discrete segments. The discrete segments may be fastenable to each other and / or hingeable relative to each other, in accordance with fastening mechanisms and hinges between different panels described herein.

[0050] The parting lines of the panels and / or the segments thereof may extend along a longitudinal axis of the vehicle (i.e., extending from the rear of the vehicle to tire front of the vehicle). Longitudinally extending parting lines may generally correspond, in location, to a boundary between the driver side (e g., left side) of the vehicle and the passenger side (e g., right side) of the vehicle. The present disclosure contemplates that no such correspondence may be required, and parting lines may be located anywhere along the plurality of panels.

[0051] The parting lines of the panels and / or the segments may extend along a transverse axis of the vehicle (i.e., extending from a left side of the vehicle to a right side of the vehicle). Transversely extending parting lines may generally correspond, in location, to boundaries between the first row passenger compartment, the second row passenger compartment, the third row passenger compartment, the cargo compartment, or any combination thereof. The present disclosure contemplates that no such correspondence may be required, and parting lines may be located anywhere along the plurality of panels.

[0052] The plurality of panels and / or the segments thereof may be hingedly connected to each other via one or more hinges. The hinges may function to pivotably articulate tire panels and / or segments relative to each other; selectively open or close one or more compartments of the vehicle, while maintaining attachment between adjacent panels and / or segments; or both. The hinges may include living hinges, barrel hinges, or both.

[0053] The living hinges may be formed of one or more material layers from which the cover is fabricated, as described herein. For example, a fabric layer and / or a foam layer may extend continuously along adjacent panels and / or segments, where a parting line may be formed in a structural polymer layer and optionally the fabric layer or the foam layer (whichever does not extend continuously along adjacent segments). In this regard, the fabric layer and / or tire foam layer may provide pivotal flexure of a panel and / or segment relative to an adjacent panel and / or segment, unencumbered by the rigidity of the structural polymer layer.

[0054] The present disclosure contemplates that the cover may be formed with a generally planar portion extending longitudinally and transversely along the top and / or sides of the vehicle and one or more curved or angled portions at one or more edges of the generally planar portions, such as extending betw een and / or over the top and sides of the vehicle. Hie curved or angled portions may generally contour the frame of the vehicle (e.g., the roof rails, window header beam, roll bars, or any combination thereof) to provide a generally flush fitment with doors and windows and to provide an overall favorable aesthetic appearance to the cover.

[0055] The living hinge may be formed along a generally planar portion of the panels and / or segments and any curved or angled portions may be free of the living hinge. Thus, the living hinge may be free of material connections out-of-plane of the pivot axis, which could restrict pivotal movement.

[0056] The semi-rigid vehicle cover may comprise one or more elastic reinforcement elements. The elastic reinforcement elements may function as a part of the living hinge, to reinforce the living hinge, to extend the service life of the living hinge, to prevent water intrusion, or any combination thereof. The elastic reinforcement element may be fabricated from an elastomeric polymer. Tire elastic reinforcement element may be located between two or more layers of the cover, within tire parting line between structural polymer layers of adjacent segments, over structural polymer layers of adjacent segments, or any combination thereof. The elastic reinforcement element may be fixed to the semi-rigid vehicle cover by stitching, riveting, an adhesive, welding, or any combination thereof.

[0057] Tire elastic reinforcement element may be in the form of one or more strips extending along the parting line and between adjacent segments. In this regard, the elastic reinforcement element may extend continuously along a length of tire parting line or may include two or more elastic reinforcement elements each extending along respective lengths of the parting line. The elastic reinforcement element may have a width that is greater than (e.g., about 5 mm or less, 4 mm or less, 3 mm or less, 2 mm or less, or even 1 mm or less) a width of the parting line. The strip may be located over the structural polymer layer of adjacent segments, between the structural polymer layer and the foam layer, between the foam layer and tire fabric layer, over the fabric layer, or any combination thereof.

[0058] The elastic reinforcement element may comprise two opposingly oriented channels (e.g., C-shaped channels) for receiving one or more of the layers of two adjacent panels and / or segments. The channels may be fixed to the one or more layers by riveting, stitching, welding, adhesive, or any combination thereof. The two opposingly oriented channels may be connected by a strip extending therebetween.

[0059] Tire barrel hinges may connect adjacent segments. The barrel hinges may include two or more, three or more, or even four or more barrel hinges distributed along the parting line. The barrel hinges may comprise a first leaf attached to one panel and / or segment and a second leaf attached to the other panel and / or segment.

[0060] The leaves may be located onto or between one or more material layers of the cover. In one aspect, the leaves may be located onto a fabric layer and exposed within the cabin of the vehicle. In another aspect, the leaves may be located between a fabric layer and a foam layer. In another aspect, the leaves may be located between a foam layer and a structural polymer layer. In another aspect, the leaves may be located onto the structural polymer layer and exposed on the exterior of the vehicle.

[0061] The barrel hinge may be fixated by one or more fasteners (e.g., bolts or rivets). The fasteners may extend through one or more of the layers and ultimately through the barrel hinge. The fasteners may extendthrough or from a rigid reinforcement element described herein and ultimately through the barrel hinge (e.g., through the leaves of tire barrel hinge).

[0062] The first panel may function to cover a top of the first row passenger compartment, a second row passenger compartment, a third row passenger compartment, a cargo compartment, or any combination thereof (otherwise referred to herein as '‘compartments”). The first panel may comprise one or more different segments associated with each of the foregoing and / or delineations between a driver side (e.g., left side) and a passenger side (e.g., right side) of the vehicle.

[0063] One or more of the plurality of panels may include a window. The window may be removable. Hie window may be manipulated into an open position and a closed position. The window may slide between the open and closed positions. The window may hingedly rotate between the open and closed positions.

[0064] The plurality of panels may include one or more tracks. The tracks may receive the window. The window may slide into, out of, and / or within the one or more tracks. The tracks may be formed by the thermoforming described herein.

[0065] The window may be fastened to the plurality of panels by stitching, welding, an adhesive, or any combination thereof.

[0066] Two or more of the plurality of panels may be continuous with each other. That is, two or more of the plurality of panels may be monolithic with each other.

[0067] Two or more of the plurality of panels may comprise fasteners for fastening the same together. The fasteners may include bolts, zippers, snaps, channels / tracks and inserts, hook-and-loop fasteners, snap-fit buckles, bolts, latches (e.g., draw latches, pivoting latches (e.g., L-shaped pivoting latches), or both), guide pins, or any combination thereof.

[0068] One or more of the plurality of panels may comprise one or more flaps. The one or more flaps may fold over a parting line between adjacent panels and / or segments. Tire one or more flaps may function as a primary fastening mechanism or a secondary fastening mechanism.

[0069] As a primary fastening mechanism, tire one or more flaps may comprise the fasteners discussed above. For example, a hook-type fastener may be located on a flap of a first panel, a loop-type fastener may be located on a surface of a second panel, the flap may be folded over the interface of the first and second panels, and the first and second panels may be fastened by a hook-and-loop connection thereof.

[0070] As a secondary fastening mechanism, the one or more flaps may fold over a primary' fastening mechanism of adjacent panels. This may be advantageous where the primary fastening mechanism may not be watertight, such as a zipper. In this regard, the flap may cover the primary fastening mechanism and divert water, wind, or the like from penetrating the primary fastening mechanism. Moreover, the flap may provide for a surface that covers the primary fastening mechanism and hide the same to impart an aesthetically pleasing appearance.

[0071] The plurality of panels may comprise one or more fasteners and / or holes for accepting fasteners. The foregoing may be employed for fastening the plurality of panels to the vehicle. The plurality of panels may fasten to a frame of the vehicle, one or more structural elements described herein, one or more body panels of the vehicle, or any combination thereof.

[0072] It is understood that the fastening mechanisms employed by each of the plurality of panels may depend on the parts of the vehicle to which the panels cover and / or engage. In some aspects, fastening mechanisms may be present on the vehicle, such as holes for accepting fasteners such as bolts. In some aspects, fastening mechanisms may be provided by structural elements that are installed on the vehicle prior to installation of the semi-rigid cover. In some aspects, fastening mechanisms may be formed into the vehicle, such as drilling holes to accept bolts. In some aspects, fastening mechanisms may employ non- invasive techniques to attach to the vehicle, such as straps that extend around the frame of the vehicle.

[0073] Tire semi-rigid vehicle cover may be employed with one or more structural elements that mount to the frame of the vehicle. The structural elements may provide engagement and / or support surfaces with the semi-rigid vehicle cover, protect the vehicle cover from damage that may otherwise occur with direct engagement with a frame of the vehicle, provide mounting points for fastening the semi-rigid vehicle cover to the vehicle, or any combination thereof.

[0074] The structural elements may include one or more of front door surrounds, rear door surrounds, pillar brackets, rear comer panel brackets, crossmembers (e.g., spanning across rear comer panel brackets), the like, or any combination thereof.

[0075] The stmctural elements may be fabricated from a polymer. Tire structural elements may be fastened to the vehicle (e.g., to the frame of the vehicle) via fasteners (e.g.. bolts).

[0076] The semi-rigid vehicle cover described herein may be used with or without these types of stmctural elements.

[0077] Tire various fastening mechanisms may be understood from the examples provided below. The following examples are not intended to be limiting. The semi-rigid vehicle cover may comprise one or any combination of the following fastening mechanisms. The fastening mechanisms may be understood as corresponding with the vehicle year, make, and / or model on which the semi-rigid vehicle cover is installed. That is, different vehicle builds may call for different fastening mechanisms.

[0078] One or more of the plurality of panels and / or segments may comprise guide pins. The guide pins may align tire panels and / or segments with respect to each other and / or align the panels and / or segments with respect to the vehicle. The guide pins may locate into holes formed in the panels and / or segments, the vehicle, or both. Hie guide pins may function as alignment tools. Fastening of the plurality of panels and / or segments to each other and / or the vehicle may employ guide pins with one or more other fastening mechanisms described herein.

[0079] One or more fasteners may extend through two adjacent panels and / or segments to connect the same together. Tire fasteners may include bolts. Nuts may screw onto an end of the bolts. Typically, the nuts may screw onto the bolts from the interior of tire cabin, although the present teachings contemplate that the nuts may screw onto the bolts from the exterior of the cabin.

[0080] One or more fasteners may extend through one or more panels and / or segment and into the vehicle (e.g., the frame of the vehicle). The fasteners may locate into holes (e.g., threaded holes) that are provided as standard features from original equipment manufacturers for securement of the conventional soft and / or hard top covers described herein. The holes may be present on the roof rails, crossmembers extending between roof rails, window header beams, pillars, or any combination thereof. The fasteners may include bolts.

[0081] The panels and / or segments may comprise one or more latches. The latches may function to engage with adjacent panels and / or segments, the vehicle, or both. The latches may include draw latches, rotating latches, or both. The latches may engage adjacent panels and / or segments, the vehicle, or both.

[0082] The latches may be located onto the fabric layer (i.e., within the cabin of the vehicle). In this regard the latches may be accessible within the cabin of the vehicle. Although, the present teachings contemplate that the latches may be located onto the structural polymer layer and exposed to the exterior of the vehicle.

[0083] The draw latches may comprise pivoting elements that impart tension between the segments and the vehicle.

[0084] The rotating latches (e.g., L-shaped rotating latches) may rotate to engage the vehicle frame (e.g., roof rails, crossmembers, the window header beam, and tire like) and / or adjacent panels and / or segments. The rotating latches may rotate onto an engagement surface which may compress the foam and fabric layers between the structural polymer layer and the vehicle.

[0085] Typically, crossmembers and / or window header beams for the sports utility vehicles described herein may comprise one or more engagement features (e.g., rigid surfaces, bars, etc.) for draw latch and / or rotating latch engagement. In this regard, the latches may be located to correspond to the location of these engagement features.

[0086] One or more of the panels and / or segments may comprise one or more rigid strips (e.g., a relatively rigid rubber) that can be inserted into a channel defined in one or more other panels and / or segments and / or the vehicle. In at least some sports utility vehicles channels may be present extending around at least a portion of the cargo area. Typically, installation of tire rigid strips within the channels may involve rotating the rigid strips into the channel to tension tire panels and / or segments.

[0087] One or more of the panels and / or segments may comprise a channel (e.g.. a C-shaped channel). One or more of the panels and / or segments may comprise a cylindrical “bead.” The cylindrical bead maybe longitudinally fed into the channel. The same may be understood as a mechanism for attaching windows to one or more of the panels.

[0088] Any hinge leaves, fasteners, or otherwise described above that are exposed to the exterior of the structural polymer layer may locate within recesses formed in the structural polymer layer. The recesses may be covered with caps that hide these elements, avoid aerodynamic effects of the recesses, provide weather sealing, or any combination thereof. Tire caps may be provided with one or more protuberances that snap-fit or friction-fit into the recesses.

[0089] The panels and / or segments may comprise one or more rigid reinforcement elements. The rigid reinforcement elements may function to anchor and / or reinforce fasteners extending through the cover as well as hardware (e.g., barrel hinges, latches, etc.) to which the fasteners attach. Although the present disclosure contemplates fasteners extending through both the structural polymer layer and rigid reinforcement elements, one advantage of tire rigid reinforcement elements may be in avoiding the heads of fasteners from being exposed on the exterior of the structural polymer layer and / or providing a possible point of water intrusion by extending fasteners through tire structural polymer layer. In this regard, the rigid reinforcement elements may be provided between layers (e.g., between the structural polymer layer and the foam layer, or between the foam layer and the fabric layer) and thus hidden from view.

[0090] At least one goal of the present teachings is to provide a lightweight cover and thus, while heavier materials (e.g., fiber-reinforced thermoset polymer, metals, and the like) may be substantially avoided by the cover of present teachings, it is contemplated that a relatively small quantity of heavier materials, such as the rigid reinforcement elements, may not appreciably increase the weight of the cover.

[0091] The rigid reinforcement elements may be fabricated from metal, polymer (e.g., thermoset polymer, optionally fiber-reinforced), or both. The rigid reinforcement elements may be generally planar. The rigid reinforcement element may comprise one or more holes for accepting one or more fasteners, respectively. Tire rigid reinforcement element may comprise a fastener integrally formed thereto (e.g., cast, molded, welded, 3D printed, or the like). The rigid reinforcement elements may be fixed by the extension of fasteners through layers of the cover and / or clamping of layers between the rigid reinforcement element and a structure (e.g., a barrel hinge, latch, or the like). The rigid reinforcement elements may be fixed by an adhesive. The rigid reinforcement elements may be fixed by physical pockets or barriers formed in one or more of the layers. One or any combination of tire foregoing approaches may be utilized.

[0092] FIG. 1A and FIG. IB illustrate a semi-rigid cover 10 according to the present teachings. The semirigid cover 10 is installed on a vehicle 12. Hie semi-rigid cover 10 includes a first panel 14 covering a top of the vehicle 12, and a second 16 and third panel 18 covering the passenger and driver side of the vehicle 12. The second and third panels 16, 18 include windows 20 and are fastenable to the first panel 14. The firstpanel 14 includes pillar covers 22 that arc continuous with the first panel 14. A rear hatch 24 is fastcnablc to the first panel 14.

[0093] FIG. 2 illustrates a semi-rigid cover 10 having first, second, and third panels 26, 28, 30. Parting lines between the panels are shown. The second and third panels 28, 30 are pivotable relative to each other and relative to the first panel 26.

[0094] FIG. 3 illustrates the layered arrangement of the semi-rigid cover 10. The semi-rigid cover 10 has a structural polymer layer 32, a foam layer 34, and a fabric layer 36. Preferably, the structural polymer layer 32 is oriented toward the exterior of the cabin and the fabric layer 36 is oriented toward the interior of the cabin, but the present teachings contemplate the opposite arrangement. The foam layer 34 may or may not be present.

[0095] It is understood that the above description is intended to be illustrative and not restrictive. The explanations and illustrations presented herein are intended to acquaint others skilled in tire art with the invention, its principles, and its practical application.

[0096] Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Many embodiments as well as many applications besides the examples provided herein will be apparent to those of skill in the art upon reading the above description.

[0097] Accordingly, the specific embodiments of the invention set forth herein are not intended as being exhaustive or limiting of the teachings. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0098] The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0099] Tire disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes.

[0100] Plural elements can be provided by a single integrated element. Alternatively, a single element might be divided into separate plural elements.

[0101] The disclosure of “a” or “one” to describe an element is not intended to foreclose additional elements.

[0102] Tire use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least tire specified endpoints.

[0103] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints in increments of one unit provided that there is a separation of at least 2 units between any lower endpointand any higher endpoint. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as, e.g., temperature, pressure, time, and the like is, e.g., from 1 to 90, from 20 to 80, or from 30 to 70. it is intended that intermediate range values such as, e.g., 15 to 85. 22 to 68, 43 to 51, 30 to 32, etc., are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings.

[0104] For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest endpoint and the highest endpoint enumerated are to be considered to be expressly stated in this application in a similar manner.

[0105] The tenn “consisting essentially of’ to describe a combination shall include the elements, ingredients, components, or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of tire terms “comprising” or “including” to describe combinations of elements, ingredients, components, or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components, or steps.

[0106] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer, and / or section from another region, layer, and / or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. HIUS, a first element, component, region, layer, and / or section discussed below could be termed a second element, component, region, layer, and / or section without departing from the teachings.

[0107] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. For example, if the device in the drawings is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example tenn “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Claims

CLAIMSWhat is claimed is:Claim 1 : A semi-rigid cover for a vehicle, the semi-rigid cover comprising: a first layer comprised of a structural polymer and adapted to orient away from a cabin interior of the vehicle; a second layer comprised of a fabric and adapted to orient toward the cabin interior of tire vehicle; and a third layer comprised of a foam and located between the first and second layers; wherein the semi-rigid cover at least forms a roof of the vehicle.Claim 2: Tire semi-rigid cover according to Claim 1, wherein the semi-rigid cover comprises a plurality of panels, the plurality of panels including one or more of the following: a first panel adapted to cover a top of the vehicle; a second panel adapted to cover a passenger side of the vehicle; a third panel adapted to cover a driver side of the vehicle; and a fourth panel adapted to cover a rear of the vehicle.Claim 3 : Tire semi-rigid cover according to Claim 2, wherein one or more of the plurality of panels include a window.Claim 4: The semi-rigid cover according to Claim 3, wherein the window is removable or can be manipulated into an open position and a closed position; and optionally wherein the window slides between the open and closed positions or hingedly rotates between the open and closed positions.Claim 5: Tire semi-rigid cover according to Claim 4, wherein one or more of tire plurality of panels include one or more tracks for receiving the window; and wherein the window is slidable into, out of, and / or within the one or more tracks.Claim 6: The semi-rigid cover according to Claim 3, wherein the window is fastened to the plurality of panels by stitching, welding, a chemical adhesive, or any combination thereof.Claim 7 : The semi-rigid cover according to any one of the preceding claims, wherein the plurality of panels comprise fasteners for fastening the plurality of panels to each other; and wherein the fasteners include zippers, snaps, tracks and inserts, hook-and-loop fasteners, or any combination thereof.Claim 8: The semi-rigid cover according to any one of the preceding claims, wherein the plurality of panels comprise fasteners and / or holes for accepting fasteners for fastening the plurality of panels to the vehicle.Claim 9: Tire semi-rigid cover according to any one of the preceding claims, wherein at least two of the plurality of panels are continuous with each other.Claim 10: The semi-rigid cover according to any one of the preceding claims, wherein at least three of the plurality of panels are continuous with each other.Claim 11 : Tire semi-rigid cover according to any one of the preceding claims, wherein the first panel includes two, three, or even four discrete segments that are fastenable to each other; and wherein the discrete segments generally locate over a front driver seat, a front passenger seat, a rear left passenger seat, a rear right passenger seat, or any combination thereof.Claim 12: The semi-rigid cover according to any one of the preceding claims, wherein one or more of the plurality of panels comprise a structural support; optionally wherein the structural support is arranged around a window, along one or more comers or radii of the plurality of panels, along one or more edges of the plurality of panels, or any combination thereof.Claim 13 : The semi-rigid cover according to Claim 12. wherein the structural support includes a wire, a tube, a generally planar member, or any combination thereof.Claim 14: Tire semi-rigid cover according to any one of the preceding claims, wherein the first, second, and / or third layers are compression molded to form a profile of the vehicle.Claim 15: The semi-rigid cover according to any one of the preceding claims, wherein one or more of the plurality of panels comprise one or more flaps; and wherein the one or more flaps fold over an interface between adjacent panels.Claim 16: The semi-rigid cover according to any one of the preceding claims, wherein the structural polymer is a thermoplastic polyolefin.Claim 17: The semi-rigid cover according to any one of the preceding claims, wherein the foam is a polypropylene foam.Claim 18: The semi-rigid cover according to any one of the preceding claims, wherein the fabric is a non-woven fabric.Claim 19: Tire semi-rigid cover according to any one of the preceding claims, wherein tire fabric is a woven fabric.

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