Composite Soft Top Assembly with Hinged Rear Window
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Solution Overview
Problem
Current convertible roof systems face challenges with soft, flexible windows that are difficult to clean, prone to scratching, and cannot withstand car washes, especially during winter months, and hard tops are bulky and lack the open-air feel when not in use.
Innovation Solution
A composite soft top assembly featuring a flexible outer layer with hard glass or polymer side windows connected to a frame, a removable horseshoe rear window with hinges, and electronic components like a rear window defrost system, allowing for an open-air experience while maintaining structural integrity and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If soft, flexible window material is used, then the top provides an open-air feel and is lightweight, but the windows are difficult to clean, scratch easily, and cannot withstand car washes
Solution Approach 1:
The patent combines soft, flexible material with hard, durable material in a single window assembly. Specifically, a rigid or semi-rigid frame or substrate is covered with a soft, flexible material layer, creating a composite structure that provides both the durability of hard material and the flexibility/open-air feel of soft material. This composite approach resolves the contradiction by integrating the beneficial properties of both material types into one unified window component.
2Reliability
If a hard top is used, then the top provides structural integrity and durability, but it is bulky and does not provide an open-air feel
Solution Approach 1:
The patent employs a thin, flexible outer layer or covering that provides the aesthetic and functional benefits of a soft top while incorporating an underlying rigid or semi-rigid frame or substrate that provides structural support. This thin-film approach allows the top to maintain structural integrity without the bulk of traditional hard tops, and the flexible outer layer contributes to the open-air feel when the top is in the up position.
3Ease of operation
If the entire hard top is removed for open-air experience, then the open-air feel is maximized, but the top becomes bulky and difficult to store
Solution Approach 1:
The patent divides the top into separable components, allowing the soft top portion to be removed or folded back independently while the rigid frame or substrate remains attached to the vehicle. This segmentation enables the open-air experience by removing only the necessary portions rather than the entire top, significantly reducing storage space requirements compared to storing a complete hard top assembly.
4Weight of moving object
If soft rear window material is used, then the top is lightweight and flexible, but the material is difficult to move out of the way for rear access
Solution Approach 1:
The patent incorporates movable or adjustable components into the rear window assembly, such as hinges, latches, or release mechanisms that allow the rear window or associated panels to be easily opened or moved aside. This dynamic design enables occupants to access the rear of the vehicle conveniently while maintaining the lightweight and flexible characteristics of the soft top material.
Data Source
AI summary
A composite soft top assembly having a convertible roof portion that provides an open air feel with a soft, flexible outer layer. The composite soft top assembly further includes soft sides with hard glass or hard polymer materials connected to a frame, which is connected to the soft sides of the assembly. Additionally, the rear window has a removable horseshoe frame structure about which the hard rear window is connected with hinges to allow for the rear window to pivot about at least one hinge between an open and closed position. Additionally, the rear window can have a wiper or electronic wire mounts for a center high mount stop lamp. Additionally, the horseshoe frame structure allows for the connection of other electrical components such as a rear defrost system.