Abstract:
A roof structure includes a roof support longitudinally extending over a compartment area at a lateral centerline of a vehicle. A plurality of pillars support the roof support and include a transverse leg extending laterally outward from the roof support to a curved section, and a vertical leg extending downward from the curved section to a vehicle beltline. Windows are assembled to a openings that are defined by two pillars, the roof support and the vehicle beltline.

Description:
TECHNICAL FIELD 
     This disclosure relates to vehicle roofs, pillars and window structures. 
     BACKGROUND 
     Vehicle roofs are normally supported by A, B, C and, on some vehicles, D pillars that define door and window openings between the pillars and below the roof. Static or movable windows may be provided in the window openings. The tops of the pillars are joined to a roof rail located at the side edge of the roof. The windows are generally raised and lowered in tracks by a manual or power window regulator. 
     Convertible tops are available that are extended and retracted on a plurality of movable bows by side rails. The windows are generally raised and lowered by a manual or power window regulator. 
     Other types of roof structures have also been produced include removable hardtops that may include fixed windows or windows that are similar to those provided with convertible tops. In addition, roofs having removable fabric panels with plastic windows are provided for utility vehicles. 
     The above types of roof structures are effective but each have limitations and are not a flexible design. Some structures are expensive to manufacture, some do not offer an open-air option, some offer less roof crush resistance, and some are difficult to install or remove. 
     This disclosure is directed to solving the above problems and other problems as summarized below. 
     SUMMARY 
     According to one aspect of this disclosure, a roof structure is disclosed that includes a roof support longitudinally extending over a compartment area at a lateral centerline of a vehicle. A plurality of pillars support the roof support and include a transverse leg extending laterally outward from the roof support to a curved section, and a vertical leg extending downward from the curved section to a vehicle beltline. A plurality of windows is assembled to a plurality of openings that are defined by two pillars, the roof support and the vehicle beltline. 
     The roof structure may further comprise a first lip provided on a roof portion of the windows and a second lip provided on the roof support that is engaged by the first lip in an installed position and is disengaged by the first lip by pivoting the window upwardly about the roof portion. A latch may be provided at a spaced location from the second lip that retains the window in the installed position. 
     According to another aspect of this disclosure, a vehicle is disclosed that features a body defining a compartment having a beltline and a plurality of inverted U-shaped pillars connected at the beltline to opposite lateral sides of the compartment and extending over the compartment. A plurality of plates is connected to adjacent pillars at a central location. A plurality of windows is provided that have a side portion and a roof portion that are connected by a curved portion. Each window is assembled to one plate and between two adjacent pillars. 
     According to other aspects of this disclosure, the U-shaped pillars may be aluminum extrusions. The U-shaped pillars may be continuous one-piece extrusions. Alternatively, the U-shaped pillars may further comprise two side extrusions and a roof extrusion that are connected by a curved corner casting. 
     The U-shaped pillars may further comprise a plurality of side flanges extending in a fore-and-aft direction from the U-shaped pillars and a top flange extending laterally from the plates. The windows may be supported by the side flanges of adjacent U-shaped pillars and the top flange. A central portion of the side flanges may be received by the centrally located plates to connect the U-shaped pillars to the plates. A seal is attached between the windows, the side flanges and the top flanges. 
     According to another aspect of this disclosure, the forward most U-shaped pillar may be adapted to support a windshield on a support flange. The windshield may be assembled to a windshield seal and the support flange of the forward most U-shaped pillar. 
     The window may be adapted to be a removable window by providing a first lip on the roof portion of the windows and a second lip on the plates that is engaged by the first lip in an installed position and is disengaged by the first lip by pivoting the window upwardly. A latch may be provided at a spaced location on the window or window frame that retains the window in the installed position. 
     The side portions of the windows and the roof portions of the window may be separate transparent panels and the curved portions of the windows may be aluminum extrusions that define a pocket for receiving a side curtain air bag. 
     According to another aspect of this disclosure, a vehicle is disclosed that comprises a body defining a compartment having a beltline, a longitudinal roof support defining a plurality of spaced receptacles. A plurality of inverted L-shaped pillars is connected at the beltline to a lateral side of the compartment to extend over the compartment to be received by the receptacles. A plurality of windows each has a side portion and a roof portion and each window is assembled to two adjacent pillars and the roof support, respectively. 
     According to other aspects of this disclosure, the L-shaped pillars may be stamped steel clamshell assemblies. The longitudinal roof support may also be a stamped steel clamshell assembly. 
     The L-shaped pillars may include a side flange extending in a fore-and-aft direction from the L-shaped pillars. A top flange may be included that extends laterally from the roof support to receive the windows on two side flanges of adjacent L-shaped pillars and the top flange. 
     The vehicle includes a windshield that is supported on a support flange provided on a forward most one of the L-shaped pillars. A windshield seal is assembled between the windshield and the support flange. 
     The window may be removable by providing a first lip provided on the roof portion of the windows and a cooperating second lip on the roof support that is engaged by the first lip in an installed position. The window may be pivoted upwardly to disengage the first lip from the second lip. A latch may be provided at a spaced location from the first lip to retain the window in the installed position. 
     The curved portions of the windows may define a pocket for receiving a side curtain air bag. The side portions of the windows and the roof portions of the window may be separate transparent panels. 
     The above aspects of this disclosure and other aspects will be described below with reference to the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevation view of a vehicle body structure including a roof support made according to one embodiment of this disclosure. 
         FIG. 2  is an exploded perspective view of a roof support including inverted U-shaped bows. 
         FIG. 3  is a fragmentary, perspective view of two roof support bows connected by a roof support plate. 
         FIG. 4  is a cross-sectional view taken along the line  4 - 4  in  FIG. 3  with partial illustrations of adjacent glass panels in cross-section. 
         FIG. 5  is a fragmentary, perspective view of a roof support plate. 
         FIG. 6  is a fragmentary, cross-sectional view of window engaging a roof support plate. 
         FIG. 7  is a fragmentary, partial cross-section view of a U-shaped bow and roof support plate in position to be assembled. 
         FIG. 8  is a fragmentary, partial cross-section view of the roof support plate welded to a central portion of a U-shaped bow. 
         FIG. 9  is a fragmentary, exploded, perspective of a window roof support plate and transverse leg of a U-shaped bow. 
         FIG. 10  is an exploded perspective view of an alternative embodiment of a roof support structure including roof support plates and bow assemblies including vertical beams and transverse beam connected by side corner castings. 
         FIG. 11  is an exploded perspective view of a side beam, transverse beam and corner casting in position to be assembled together. 
         FIG. 12  is an exploded longitudinal elevation view of a vertical beam, a transverse beam and a corner casting. 
         FIG. 13  is an exploded perspective view of a bow assembly and windshield. 
         FIG. 14  is a cross-sectional view of a windshield secured to a windshield header. 
         FIG. 15  is an exploded traverse elevation view of a windshield header and roof support plate. 
         FIG. 16  is a partial cross-section perspective view of a transverse beam including a notch assembled to a curved corner casting and vertical beam. 
         FIG. 17  is an exploded perspective view of the notched transverse beam, curved casting and vertical beam shown in  FIG. 16  in an exploded perspective view. 
         FIG. 18  is a cross-sectional view taken along the line  18 - 18  in  FIG. 16 . 
         FIG. 19  is a fragmentary perspective view of a roof support structure showing a roof panel exploded away from a roof opening defined by adjacent inverted U-shaped bows connected by a top plate and a curved transition panel. 
         FIG. 20  is a perspective view of one inverted U-shaped bow attached to a curved transition panel. 
         FIG. 21  is a cross-sectional view of a curved transition panel including a side curtain air bag received in a receptacle defined by the curved transition panel. 
         FIG. 22  is an exploded perspective view of the roof support structure shown in  FIG. 19  with a side panel and top panel exploded away from openings defined between the adjacent inverted U-shaped bows, the top plate and curved transition panel. 
         FIG. 23  is an exploded perspective view of a unitary roof support and upper and lower clam shell parts of a plurality of L-shaped pillars. 
     
    
    
     DETAILED DESCRIPTION 
     The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts. 
     Referring to  FIG. 1 , a vehicle body structure  10  is illustrated that includes a roof support  12  that extends in the longitudinal vehicle direction. The roof support  12  is supported by a plurality of pillars  14  that are identified as A-pillar  14 A, B-pillar  14 B, C-pillar  14 C and D-pillar  14 D. The roof support  12  and pillars  14 A- 14 D form the vehicle body structure above the compartment area or passenger compartment  16  of the vehicle. A lower body assembly  20  is also illustrated in  FIG. 1  that includes lower pillars  22  and are designated A-pillar  22 A, B-pillar  22 B, C-pillar  22 C and D-pillar  22 D. The vehicle front end  24  is also illustrated and includes an upper fender support  26  and a lower fender support  28 . A rear fender support  30  is illustrated as extending between the C-pillar  14 C and D-pillar  14 D and is disposed at or near the belt line B of the vehicle. The belt line B of the vehicle is at the lower edge of the windows of the passenger compartment. The lower body assembly  20  is assembled by joining tubular beams  32  at cast nodes  36 . The upper ends of the lower pillars  22  are adapted to receive the lower ends of the pillars  14 A-D. 
     Referring to  FIGS. 2-9 , an embodiment of this disclosure is illustrated that includes a segmented roof support in conjunction with inverted U-shaped bows. Referring specifically to  FIG. 2 , a plurality of roof support plates  40  are shown disposed between adjacent inverted U-shaped bows  41 . The inverted U-shaped bows  41  include a transverse leg  42  that extends across the roof of the compartment area  16  (shown in  FIG. 1 ) and a vertical leg  43  that extends from the beltline B (shown in  FIG. 1 ) to a curved section  44  that joins the transverse leg  42  to the vertical leg  43  of the inverted U-shaped bows  41 . The roof support plates  40  include a pair of flanges  45  that are adapted to receive a central portion  46  of the transverse leg  42 . 
     A top window support flange  48  is provided on the roof support plates  40  and side window support flanges  50  are provided on the transverse leg  42  and vertical legs  43 . The window support flanges  48  and  50  are adapted to receive a seal  52  as will be described with reference to  FIG. 3  below. The roof support plates  40  are aligned along the center line C of the roof support. 
     Referring to  FIG. 3 , a pair of adjacent inverted U-shaped bows  41  are generally indicated by reference numeral  41 . The adjacent inverted U-shaped bows  41  are connected by roof support plate  40 . A top window support flange  48  is provided on the roof support plate  40  and a side window support flange  50  is provided on the adjacent inverted U-shaped bows  41 . A seal  52  is attached to the window support flanges  48  and  50 . 
     An interlock flange  54  is also provided on the roof support plates  40  above the top support flange  48 . The interlock flange  54  is used to secure a window or other panel as will be described in more detail below with reference to  FIGS. 6 and 9 . 
     Referring to  FIG. 4 , a section is taken through one of the inverted U-shaped bows and is shown with a pair of windows  56  on opposite sides of the vertical leg  43  of the bow  41 . The seals  52  are shown attached to the side window support flanges  50 . The seal  52  is disposed between the bows  41  and windows  56  to prevent seepage of air or water. 
     Referring to  FIG. 5 , a roof support plate  40  is shown that includes the pair of flanges  45  on a transversely extending side and the top window support flange  48  and interlock flange  54  on a longitudinally extending side of the roof support plate  40 . 
     Referring to  FIG. 6 , a window  56  is shown to include a window edge attachment  58 . The window edge attachment  58  can be an extruded part that is attached to an upper edge of the window  56 . While the window  56 , as illustrated, is a glass or transparent plastic panel it should be understood that the window  56  could also be an opaque or solid panel. The window attachment  58  includes an interlock lip  60  that cooperates with the interlock flange  54  of the roof support panel  40 . The window  56 , or solid panel, may be removed from the roof support by tilting the window upwardly to disengage the interlock lip  60  from the interlock flange  54 . The seal  52  is compressed when the glass panel  56  is installed and exerts an upward force on the window edge attachment  58  to hold the interlock lip  60  against the interlock flange  54 . 
     Referring to  FIGS. 7 and 8 , a roof support plate  40  is shown to be aligned with the transverse leg  42 . The side window support flange  50  of the U-shaped bow  41  is received in a slot  61  formed in a roof support  40 . The support plate  40  is shown welded to transverse leg  42  in  FIG. 8  with the side window support flange  50  being received in the slot  61  and the flanges  44  being received in the flange receiving groove  62  defined by transverse leg  42 . The support plate  40  is welded to the central portion  46  of the transverse leg  42 . 
     Referring to  FIG. 9 , a window  56 , or solid panel, is shown to include a window edge attachment  58  that defines the interlock lip  60 . The panel or window  56  is supported on the top window support flange  48  and the side window support flange  50  and is pivoted under the interlock flange  54  to secure the panel or window  56  to the roof support plates  40  and inverted U-shaped bows  41 . 
     Referring to  FIGS. 10-15 , alternative embodiments of the roof support  12  (shown in  FIG. 1 ) are illustrated that include a curved corner casting instead of the inverted U-shaped bows described with reference to  FIGS. 2-9 . 
     Referring to  FIGS. 10-13 , embodiments disclosed in which roof support plates  70  are secured between adjacent bow assemblies  72 . The bow assemblies each include a right side vertical beam  74  and a left side vertical beam  76  that are joined to a transverse beam  78 . The right side vertical beam  74  and transverse beam  78  are joined by a right side corner casting  80 . The left side vertical beam  76  and transverse beam  78  are joined together by a left side corner casting  82 . The transverse beam  78  is received between flanges  84  provided on front and rear sides of the roof support plates  70 . A top window support flange  86  is provided on the transverse beam  78  and a side window support flange  88  is provided on the right and left side vertical beam  74  and  76 . While not shown, a seal  52  is provided on the window support flanges  86  and  88  that may be similar to seal  52  shown in the embodiment  FIGS. 2-9  above. 
     Referring to  FIGS. 11 and 12 , a bow assembly  72  is shown with the left side vertical beam  76  and transverse beam  78  separated from the left side corner casting  82 . An opening  90  is provided in the transverse beam  78  for receiving a top plug end  92  that extends from the left side corner casting  82 . A side plug end  94  is received in an opening  96  defined by the left side vertical beam  76 . A corner node window support flange  98  is provided on the side of the left side corner casting  82 . 
     Referring to  FIGS. 13-15 , a transverse window such as a windshield or rear window is shown as it is intended to be attached to either a front or rear bow assembly  72 . The portion of the bow assembly illustrated includes a left side vertical beam  76  that is connected by a left side corner casting  82  to a header  104 . The transverse window  102  is secured by an adhesive or seal to a windshield header support flange  106  provided on the header  104 , the left side corner casting  82  and also to an A-pillar windshield support surface  108 . The A-pillar windshield support surface  108  is recessed to receive the window  102 . 
     Referring to  FIG. 15 , the header  104  is shown exploded away from the roof support plate  70 . The flanges  84  on the roof support plate  70  are received in grooves  109  formed in the rear edge of the windshield header  104 . The top window support flange  86  on the header  104  is received in a groove  111  defined by the roof support plate  70 . 
     Referring to  FIGS. 16-18 , alternative embodiment of a roof support is illustrated in which a notched transverse beam  110  is assembled over a portion of the curved corner casting  126 . The transverse beam  110  defines a notch  112  that is assembled over a plug end  114  of a curved corner casting  126 . An opening  116  is defined by the left side vertical beam  76  and receives a side plug end  118  of the curved corner casting  126 . A top window support flange  120  is provided on the transverse beam  110  and a side window support flange  122  is provided on the left side vertical beam  76 . A corner node window support flange  124  is provided on the side of the curved corner casting  126 . The window support flanges  120 ,  122  and  124  shown in  FIGS. 16-17  include a T-shaped edge  128  shown in  FIG. 18  that may be provided to facilitate attachment and retention of the seal  52  shown in  FIGS. 3, 4 and 6  above. It should be understood that other seal structures may be accommodated to form a seal between the bows  72 , support plates  70  and the windows  56 , or panels. 
     Referring to  FIGS. 19-22 , another embodiment is illustrated that includes a corner extrusion extending between adjacent pillars. As shown in  FIG. 19 , a roof support plate  130  is provided between adjacent pillars or adjacent inverted U-shaped bows  132 . The inverted U-shaped bows  132  are similar the embodiment described with reference to  FIGS. 2-9  and extends parallel the center line C (shown in  FIG. 2 ) of the roof support. The corner extrusion  138  is illustrated with a separable top roof panel, or window  140 . The top roof panel  140  may be a solid panel or a window. The window  14 D or panel may include a window edge attachment  142 . A latch  144  is also illustrated for securing the panel to one of the U-shaped bows  132 . Referring to  FIG. 20 , the corner extrusion  138  may include side curtain air bag receptacle  148  that is adapted to receive a side curtain air bag  150 . Referring to  FIG. 21 , the corner extrusion  138  is shown in cross-section to include a side curtain air bag receptacle  148  that in turn receives the side curtain air bag  150 . 
     Referring to  FIG. 22 , the roof support plate  136  is shown disposed between the transverse leg  134  of the adjacent U-shaped bows  132 . The corner extrusion  138  is shown at the transition from the transverse leg  134  to the vertical leg  136  of the U-shaped bows  132 . A top roof panel or window  140  is shown above the opening defined by the bows  132 , roof support plate  130  and corner extrusion  138 . The top roof panel  140  is provided with a window edge attachment  142  and latch  144  as previously described. In addition, a side panel  152  that may be a window or a solid panel is shown in position next to an opening defined by the vertical legs  136  of the U-shaped bows  132  and below the corner extrusion  138 . The side panel  152  may also include a side window edge attachment  154  and latch  144  to secure the side panel  152  below the corner extrusion. 
     Referring to  FIG. 23 , another alternative embodiment is partially shown. It is to be understood that the left side of the roof support is not shown in  FIG. 23  but is a mirror image of the structure shown on the right side. A unitary roof support  160  is provided that extends along the center line C of the roof support  160 . The unitary roof support  160  defines a plurality of pillar receptacles  162 . The unitary roof support  160  is preferably formed in a sheet metal stamping process and may be stamped from metal such as aluminum or steel. The roof support  160  also includes a plurality of L-shaped pillars  164  that may be designated A-pillars through D-pillar as previously described. The L-shaped pillars  164  include an upper clam shell part  166  and a lower clam shell part  168 . The clam shell parts  166  and  168  are joined together to form the L-shaped pillars  164 . Additional reinforcements or pillars may be provided inside the clam shell part. The upper clam shell part  166  includes upper joining flanges  170  and a lower clam shell part  168  includes lower joining flanges  172 . The upper and lower joining flanges  170  and  172  may be joined together by welds, adhesive deposits or fasteners to form a rigid support structure for the unitary roof support  160 . The L-shaped pillars  164  include a transverse leg  174  that extends from the roof support  160  to a curved area  175  where the side leg  176  extends downwardly to the beltline B (shown in  FIG. 1 ). Windows  56  or other panels may be assembled between adjacent L-shaped pillars  164  as described with reference any of the embodiments of  FIGS. 2-22 . Seals  52  are intended to be provided on support flanges. Latches and interlocking flanges are also intended to be incorporated in the embodiment of  FIG. 23  as previously described with reference to the embodiments of  FIGS. 2-22 . 
     The embodiments described above are specific examples that do not describe all possible forms of the disclosure. The features of the illustrated embodiments may be combined to form further embodiments of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of the following claims is broader than the specifically disclosed embodiments and also includes modifications of the illustrated embodiments.