Zipper less removable windows for a folding SUV soft top

A zipper less removable window system having removable windows for use with a foldable, stowable roof for a vehicle. A plurality of attachment devices of the zipper less removable window system connect the windows to the foldable, stowable roof and to the vehicle without the use of zippers. The operator zipper effort caused by traditional windows is thereby eliminated and misalignment issues present with traditional zippered windows is eliminated or reduced. The stress placed on the portions of the windows connectable to the foldable roof during installation and removal, including around curved portions of the removable window, is eliminated or reduced.

FIELD OF THE INVENTION

The present invention is directed to a window attachment system suited for selectively connecting removable windows to a foldable roof of a foldable, stowable roof.

BACKGROUND OF THE INVENTION

Foldable stowable roof tops are commonly used in sport-utility vehicles for recreational purposes. The foldable roof is typically moved between a stowed position, and a deployed position. When in the deployed position, the foldable roof protects the occupants of the vehicle from various weather conditions. The foldable roof also includes various sections which are made of a clear material to essentially function as a window, allowing the occupant of the vehicle to see outside of the vehicle. It is also sometimes desirable to open these clear window sections when weather conditions are favorable, but the occupant(s) of the vehicle may not desire to change the foldable roof to the stowed position.

Because these window sections are also foldable and/or removable, typical window crank devices and electric motors used for opening and closing a window made of glass (which is rigid and not foldable) are not suitable for use with a foldable roof. Therefore, other methods of opening the foldable window have been developed.

One of these methods is a zipper which is typically one continuous zipper that surrounds all sides of the window but one. The one side of the window which is not surrounded by the zipper is the foldable side, allowing the window to be folded from the closed to the open position. One of the drawbacks to this type of design is that typical zippers are designed for connecting two sheets of material along a substantially straight surface. These zippers are difficult to align and misalignment results in higher zipper effort. In addition, both sides of the zipper are in the same plane and the difference between the radius of the outer window connected to the zipper and the radius of the foldable roof connected to the zipper is typically the width of the zipper. This makes the zipper difficult to use around the corners of the window because there is an imbalanced amount of stress placed on the portion of the zipper connected to the window and the portion of the zipper connected to the foldable roof. Another one of the drawbacks is that the window is not removable, which necessitates clear, foldable, window sections that must be folded and secured out of the way taking up space within the vehicle and can create noise from vibrating in the wind when the vehicle is moving.

Another of these methods for opening the window is employing a removable window. Current soft windows are attached to the soft top via zippers. These prove to be quite cumbersome to use. It is difficult to align the zipper end into the box end of the corresponding zipper on the soft top. Secondly, the zipper can be difficult to close and/or open as the efforts can be quite high due to zipper misalignment between the soft top and window assembly. This is caused by manufacturing issues and/or tolerances such as in alignment during the sewing process that is used to attach the zippers to the soft top and windows. Misalignment can cause the zipper teeth to skip thereby making the zipping motion efforts high. Any variation of the zipper alignment can result in higher zipper efforts around at least the upper rear corner where the curved portion of the window is connectable to the roof resulting in installation difficulty of the window. Another issue from zipper teeth skipping and/or misalignment of zipper halfs is that this can cause the window to not be closed all the way resulting in gaps where water and air can enter the vehicle.

Accordingly, there exists a need for removable windows including zipper less attachments which are suitable for providing a selective connection between a foldable roof and the removable windows having various straight and curved areas.

SUMMARY OF THE INVENTION

The present invention is directed to a zipper less removable window assembly having window attachment devices for eliminating zippers for use with a foldable, stowable roof for a vehicle, where the foldable roof includes one or more removable windows made of a plastic material such as polyvinyl chloride (PVC). The window attachment devices are easier to use and reduce the stress/effort caused by conventional zippers which are difficult to operate.

The foldable, stowable roof is connected to a vehicle, and has at least one curved portion and at least one straight portion. Additionally, the removable window is also connected to the vehicle, and the removable window has at least one curved portion and at least one straight portion. The curved portion of the foldable, stowable roof generally corresponds to the shape of the curved portion of the removable window. The removable window comprises a plurality of attachment devices selectively connecting the foldable, stowable roof to the removable window. Each of the plurality of attachment devices is zipper less and has a first half connected to the foldable, stowable roof and a second half connected to the removable window. The plurality of window attachment devices connect the left side quarter window, right side quarter window, and rear window to the vehicle and the foldable, stowable roof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring generally toFIGS. 1-4, a typical zipper, shown generally at10, is connected to a deck side strip/foldable roof12and a window14, e.g., a quarter window. Such conventional windows with zippers are problematic. The zipper10can be connected to the foldable roof12and the window14by a first seam of a first half16and can be connected to the window14through the use of a second seam of a second half18. The zipper start location is critical in relation to the corresponding start on the window and yet variation is common such as at least +/−10 millimeters of variation. This is caused by sewing tolerances during manufacturing and other manufacturing issues. In addition, the placement of the zipper10on the deck side strip is critical to the corresponding zipper half on the window14and yet variation is common such as at least +/−10 millimeters of variation. Another issue with typical zipper systems is that the alignment of the zipper to the quarter window14can vary, such as at least +/−5 millimeters of variation, and does not align perfectly with a “V” notch indicator in the window fabric reinforcement. In particular, there is misalignment with the second seam/zipper and the concentric window fabric reinforcement in the corner area of the window14.FIG. 1illustrates a conventional first half16of a zipper on a foldable roof12having a zipper start location that can vary by at least +/−5 mm from the edge.FIG. 2illustrates a conventional second half18of a zipper on a window14having a zipper start location that can vary by at least +/−5 mm.

FIG. 3illustrates installation of the window14zipper start into the deck side box end of the foldable roof12. This can be difficult, compounded by the variations and misalignment of these features, resulting in the zipper teeth to skipping, thereby making the zipper10motion efforts high. Further, any variations of the zipper manufacturing alignment can result in high zipper10efforts around the corner portions, e.g., around the upper rear corner depicted inFIG. 4, shown generally at20, resulting in installation difficulty of the window14.

Referring generally toFIGS. 5-15, there is provided a zipper less removable window assembly, shown generally at100, connected to a vehicle11. The zipper less removable window assembly100includes a plurality of removable windows, shown generally at102, having a plurality of window attachments, where the plurality of removable windows102includes a rear window104, a left quarter window106, and a right quarter window108. The plurality of window attachments allows for selectively connecting the plurality of removable windows102to a foldable, stowable roof when it is desired to close off the vehicle interior from the outside environment.

Referring more particularly toFIG. 5is a schematic incorporating a foldable, stowable roof110connected to the zipper less removable window assembly100without the use of zippers. The plurality of removable windows102are connectable to the foldable, stowable roof110and to the vehicle11using the plurality of window attachments having no zippers.

Referring more particularly toFIG. 6,FIG. 6is an enlarged sectional view taken along section A-A ofFIG. 5depicting the left quarter window106coupled to the foldable, stowable roof110. The left quarter window106is a zipper less removable window that connects to the vehicle and connects to the top deck110acurved area of the foldable, stowable roof110and connects to a deck side strip116. The left quarter window106has a quarter window glass112, most preferably, made of PVC. A quarter window carrier114is connected along the upper longitudinal edge of the quarter window glass112. Most preferably, a longitudinal recess or notch113is provided in the quarter window carrier114and the quarter window glass112is affixed to one or more abutting surfaces in the recess, e.g., using adhesive and/or a film adhesive, most preferably, sewing and/or combinations thereof. Preferably, the quarter window carrier114is formed of molded plastic, e.g., composite material, reinforced fibers, etc.

The quarter window carrier114has a first channel portion, shown generally at115, that is generally C-shaped. The first channel portion115is open on at least one end to slidably receive a bulb portion of a first ‘P’ welt retainer therein. A deck side strip116of fabric is connected to the top deck110aof the foldable, stowable roof110, most preferably, sewn to the top deck110aat one end, and is connected to the first ‘P’ welt retainer118toward the other end. The deck side strip116is wrapped around the first ‘P’ welt retainer118and connected thereto, e.g., using adhesive and/or, most preferably, sewing the first ‘P’ welt retainer118in a pocket formed by the deck side strip116. The first channel portion115of the quarter window carrier114is suitably sized to allow selective sliding of the elongated channel115along the length of the first ‘P’ welt retainer118and to retain the first ‘P’ welt retainer118longitudinally within the channel115while preventing undesirable lateral movement of the first ‘P’ welt retainer118out of the channel115, including, moving laterally out of the channel115.

The quarter window carrier114further has a second channel portion119that is generally U-shaped forming an elongated open channel that is generally angled downward and outward from the first channel portion115. The end of the top deck110ais connected to a top deck retainer120and binding top deck122portion. The top deck retainer120is selectively received within the second channel portion119. When it is desired to connect the quarter window glass112to the foldable, stowable roof110, the top deck110ais folded down over the outward side of the quarter window carrier114and the top deck retainer120is snapped into the second channel portion119. When it is desired to remove the quarter window glass112, an operator disengages the top deck retainer120from the second channel portion119. Preferably, the quarter top deck retainer120is formed of molded plastic, e.g., composite material, reinforced fibers, etc.

The right quarter window108and corresponding features are substantially mirror image to the left quarter window106and corresponding features.

Referring more particularly toFIG. 7,FIG. 7is an enlarged sectional view taken along section B-B ofFIG. 5depicting the rear window104coupled to the foldable, stowable roof110. The rear window104is a zipper less removable window that connects to the vehicle and connects to a rear valence top deck132curved rear area of the rear top deck110bof the foldable, stowable roof110. The rear window104also connects to a rear side strip128. The rear window104has a rear window glass124, most preferably, made of PVC. A rear window carrier126is connected along the upper longitudinal edge of the rear window glass124. Most preferably, a longitudinal recess or notch125is provided in the rear window carrier126and the rear window glass124is affixed to one or more abutting surfaces in the recess, e.g., using adhesive and/or a film adhesive.

The rear window carrier126has a third channel portion, shown generally at127, that is generally C-shaped. The third channel portion127is open on at least one end to slidably receive a bulb portion of a second ‘P’ welt retain therein. The rear side strip128of fabric is connected to the rear top deck110bof the foldable, stowable roof110, most preferably, sewn to the rear top deck110bat one end, and is connected to the second ‘P’ welt retainer130toward the other end. The rear side strip128is wrapped around the second ‘P’ welt retainer130and connected thereto, e.g., using adhesive and/or sewing the second ‘P’ welt retainer130in a pocket formed by the rear side strip128. The third channel portion127of the rear window carrier126is suitably sized to allow selective sliding of the elongated channel127along the length of the second ‘P’ welt retainer130and to retain the second ‘P’ welt130longitudinally within the channel127while preventing undesirable lateral movement of the second ‘P’ welt retainer130out of the channel127, including, moving laterally out of the channel127.

The end of the rear top deck110bis connected to a rear valance top deck132. Most preferably, an end of the rear valance top deck132and an end of the rear side strip128are sandwiched between an end of the rear top deck110band a liner of the upper horizontal rear support bar of the vehicle, and connected together, e.g., sewn together.

The rear window carrier126further has a fourth channel portion134that is generally U-shaped forming an elongated open channel that is generally angled downward and outward from the third channel portion127. The lower end of the rear valance top deck132is connected to a rear top deck retainer136and rear binding top deck138portion. The rear top deck retainer136is selectively received within the fourth channel portion134. When it is desired to connect the rear window glass104to the foldable, stowable roof110, the rear valance top deck132is folded down over the rearward side of the rear window carrier126and the rear top deck retainer136is snapped into the fourth channel portion124. When it is desired to remove the rear window glass104, an operator disengages the rear top deck retainer134from the fourth channel portion134. Preferably, the rear window carrier126and rear binding top deck138is formed of molded plastic, e.g., composite material, reinforced fibers, etc.

Referring more particularly toFIG. 8,FIG. 8is an enlarged sectional view taken along section C-C ofFIG. 5depicting the left quarter rear window106coupled to the rear window104toward the left rear corner of the vehicle. A rear window side carrier140is connected along the vertical edge of the rear window glass124. Most preferably, an elongated recess or notch141is provided in the rear window side carrier140and the rear window glass124is affixed to one or more abutting surfaces in the recess, e.g., using adhesive and/or a film adhesive. The left quarter window106has a quarter window panel144of fabric connected to a rear quarter window retainer142. The rear quarter window retainer142is received in a fifth channel portion143formed in the rear window side carrier140that is generally U-shaped forming an elongated open channel to selectively receive and retain the elongated rear quarter window retainer142therein. Preferably, the rear window side carrier140and/or rear rear quarter window retainer142is formed of molded plastic, e.g., composite material, reinforced fibers, etc.

The right hand side of the rear window104coupled to the right quarter window108and all of the corresponding features are substantially mirror image to the left quarter window106and corresponding features coupled to the rear window104and corresponding features depicted inFIG. 8.

FIG. 9is a schematic for the vehicle ofFIG. 5identifying additional cross sections depicted inFIGS. 10-12.

Referring more particularly toFIG. 10,FIG. 10is an enlarged sectional view taken along section D-D ofFIG. 9depicting the left quarter rear window106coupled to a removable door rail148. This provides the vertical connection along the front leading edge of the left quarter window106adjacent the rear edge of the door of the vehicle. The quarter window panel144of the left quarter window106is wrapped around and connected to a front quarter window retainer146, e.g., using adhesive and/or sewing the front quarter window retainer146in a pocket formed by the quarter window panel144leading edge. The front quarter window retainer146is L-shaped and elongated. A sixth channel portion145that is in the removable door rail148that is generally U-shaped forming an elongated open channel to selectively receive and retain one of the legs of the L-shaped front quarter window retainer146.

The right quarter window108and right removable door rail and corresponding features are substantially mirror image to the left quarter window106and removable door rail147and corresponding features depicted inFIG. 10.

Referring more particularly toFIG. 11,FIG. 11is an enlarged sectional view taken along section E-E ofFIG. 9depicting the quarter window panel144of the left quarter window106connected, e.g., by adhesive and/or sewing a quarter window belt retainer150. The quarter window belt retainer150is located along the bottom of the left quarter window106for engaging between, and being retainable by, a belt rail152of the vehicle body and a quarter panel outer154of the vehicle body. The belt rail152is connected to the quarter panel outer154and a quarter panel inner156. The outward end of the belt rail152is curved to create a recess that is elongated for receiving and retaining the corresponding elongated quarter window belt retainer150. This provides the horizontal connection along the bottom edge of the left quarter window106to the vehicle.

The right quarter window108and corresponding features are substantially mirror image to the left quarter window106and corresponding features depicted inFIG. 11.

Referring more particularly toFIG. 12,FIG. 12is an enlarged sectional view taken along section F-F ofFIG. 9depicting the rear window104for selectively coupling to a rear panel swing gate inner158. The rear window104comprises a rear window lower valence162connected to a third ‘P’ welt retainer164and a binding rear window166. The seventh channel portion is generally C-shaped and open on at least one end to slidably receive a bulb portion of the third ‘P’ welt retainer164therein. The rear window lower valence162of fabric is connected to the ‘P’ welt retainer164, e.g., using adhesive and/or sewn and/or sewing the third ‘P’ welt retainer164in a pocket formed by the fabric of the rear window lower valence162. The seventh channel portion165of the tailgate bar167is suitably sized to allow selective sliding and retention of the elongated third ‘P’ welt retainer164longitudinally within the channel165while preventing undesirable lateral movement of the third ‘P’ welt retainer164out of the channel165, including, moving laterally out of the channel165. This provides the horizontal connection along the bottom edge of the rear window104adjacent to the rear swing gate of the vehicle. A swing gate weather strip168, e.g., a bulb seal, is also provided to provide a sealing function between the tailgate bar167and a panel swing gate outer of the vehicle body160.

Referring generally toFIGS. 5-15, in an embodiment of the present invention, the installation of the zipper less removable window assembly10will now be explained. When it is desired to close the removable rear window104a user aligns and slidably engages the rear window carrier126on the top of the window onto the rear side strip128where the second ‘P’ welt retainer126is located. The user slides the removable window104on the rear valance top deck132until the window is fully engaged across the length of the valance132. The user pre-engages the tail gate bar167onto the third ‘P’ welt retainer164at the bottom of the rear window104. The user slides the tail gate bar167on the front window ‘P’ welt retainer164until the tail gate bar167is fully engaged across the length of the third window ‘P’ welt retainer164. Then the user rolls the tail gate bar167into the tail gate bar clip170on the vehicle body. The user aligns the rear window corner retainer, e.g., binding rear window166with the tailgate clip170and snaps the rear window corner retainer into the tailgate clip. If the quarter windows do not require installation, the top deck110b/132can then be installed at the rear window104, as explained in greater detail below.

The installation of a quarter window will now be explained, e.g., left side quarter window106. When it is desired to close the removable left quarter window106(and/or right rear quarter window108) a user aligns the quarter window carrier114on the top of the quarter window onto the deck side strip116at the upper rear corner. The user slides the quarter window carrier114along the deck side strip116until the left quarter window106is fully engaged along the length of the deck side strip116. The user pre-engages the front quarter window retainer146into the removable door rail148until the front quarter window retainer146is fully engaged into the removable door rail148. The user then tucks the upper quarter window flaps between the deck side strip116and the top deck110aat the front, e.g., toward direction of vehicle hood. The user aligns and engages the top deck retainer120to a quarter window upper front corner retainer. Then aligns and engages the top deck retainer120to the quarter window carrier114from the front corner across the top of the window. The top deck retainer120is engaged to the quarter window carrier114along the entire length. The user folds down the roof edge110.

The user then aligns and inserts the quarter window belt retainer into the vehicle body belt rail at the lower front corner, e.g., in the direction toward vehicle hood, until the quarter window belt retainer is fully inserted into the vehicle body belt rail152. The user aligns and engages the quarter window retainer150into the vehicle body belt rail152at a lower front corner of the quarter window106. The user inserts the quarter window retainer150until the quarter window retainer150is fully engaged into the vehicle body belt rail152.

The user aligns and engages the rear quarter window retainer142into the rear window side carrier140. The user aligns and engages the quarter rear belt rail retainer150into the vehicle body belt rail152at the lower rear corner of the vehicle.

The installation of the top deck at the rear window will now be explained. The user aligns and engages the rear top deck retainer136into the rear window carrier126at the upper corner, e.g., upper right corner on the rear of the vehicle. The user engages the rear top deck136retainer into the rear window carrier126along the entire length thereof.

In the fully installed position, the top deck is folded down over the top of the removable windows to help create a weather tight seal.

When it is desired to open at least one of the windows the steps described above can be facilitated in reverse to disconnect and remove the window(s) from the foldable, stowable roof.

It is understood that one or more removable windows can be selectively installed and removed. By way of non-limiting example, when it is desired by the user that the rear window be removed the quarter windows can selectively remain connected to the foldable, stowable roof.

The removable window having the zipper less attachment design of the present invention facilitates the opening and closing of the removable window. Accordingly, there is a significant benefit to the positioning of the attachment devices and along all the edges of the removable windows that are zipper less.