Open frame vehicle multifunctional sport tube

A roof rail assembly for a motor vehicle having an open frame vehicle architecture includes a side air curtain fixedly coupled with an elongated hollow sport tube extending along a longitudinal axis of the motor vehicle. The sport tube comprises a two-piece multi-gage tube extending along a longitudinal length of an occupant compartment of the motor vehicle. The side airbag curtain is fixedly coupled with the sport tube, the side airbag curtain having a stowed condition and an inflated condition. An integrated seal carrier is fixedly coupled with the sport tube and extends laterally outboard of the motor vehicle, the integrated seal carrier comprising a removable roof sealing member and a removable door window seal, wherein the removable roof sealing member and a removable door window seal are independent of one another.

FIELD OF THE INVENTION

The present invention generally relates to a motor vehicle having an open frame vehicle architecture and, more particularly, to a roof rail having an elongated hollow sport tube to which is attached a side airbag curtain and an integrated seal carrier for interface with a removable roof assembly and a frameless retractable window of a removable side door assembly.

BACKGROUND OF THE INVENTION

Traditional motor vehicle architecture may include a side air curtain/curtain air bag (SAC/CAB) that interfaces with a soft/flexible headliner and hard trim on the upper pillar trim. The soft/flexible headliner allows for the actuation of the SAC/CAB during an impact event. Certain nontraditional motor vehicles may employ an open frame vehicle architecture that provides the ability for a roof assembly and side door assemblies to be removed by the customer. Thus, motor vehicles that employ an open frame vehicle architecture require unique design configurations to provide such additional occupant restraining features for occupants via a side air curtain restraint, where traditional applications for a SAC/CAB may not be entirely appropriate. In additional, unique design configurations are required to provide effective sealing for the removable roof assembly and the frameless retractable windows of the removable side door assemblies.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a roof rail assembly for a motor vehicle has an open frame vehicle architecture including a side air curtain fixedly coupled with an elongated hollow sport tube extending along a longitudinal axis of the motor vehicle. The sport tube comprises a two-piece multi-gage tube extending along a longitudinal length of an occupant compartment of the motor vehicle. The side airbag curtain is fixedly coupled with the sport tube, the side airbag curtain having a stowed condition and an inflated condition. An integrated seal carrier is fixedly coupled with the sport tube and extends laterally outboard of the motor vehicle. Each of the integrated seal carriers comprises a removable roof sealing member and a removable door window seal, wherein the removable roof sealing member and the removable door window seal are independent of one another.

Embodiments of the first aspect of the present disclosure can include any one or a combination of the following features:The sport tube is fabricated from a metal material.The sport tube comprises an inboard side and an outboard side, wherein the side airbag curtain is fixedly coupled with the inboard side of the sport tube and the integrated seal carrier is fixedly coupled with the outboard side of the sport tube.The sport tube comprises a forward length having a rearward end and a rearward length having a forward end, wherein either of the rearward end of the forward length or the forward end of the rearward length comprises a reduced outer diameter that may be received within an inner diameter of the other to form a tent-poled joint.The tent-poled joint is seam welded after assembly.The sport tube is hot formed after the tent-poled joint is formed.The side airbag curtain is coupled to an inboard side of the sport tube, and the side airbag curtain extends substantially along a longitudinal length of the sport tube.A plurality of discrete integrated seal carriers are each disposed along a length of the sport tube proximate the location of a retractable door window of each of a plurality of removable side door assemblies, wherein each of the plurality of integrated seal carriers has a longitudinal length substantially corresponding to a location and a longitudinal length of the retractable door window of one of the removable side door assemblies, respectively.The removable roof sealing member of the plurality of integrated seal carriers defines in part an upwardly facing sealing plane along the longitudinal axis of the motor vehicle for interface with a sealing member on a removable roof assembly and the removable door window seal defines a downwardly facing sealing plane for interface with a retractable door window, the removable roof sealing member and the removable door window seal acting independently of each other.

According to another aspect of the present invention, a roof rail assembly for a motor vehicle having an open frame vehicle architecture comprises an elongated hollow two-piece sport tube extending along a longitudinal axis of the motor vehicle, the sport tube comprising an inboard side and an outboard side, and a forward end of the sport tube extends from an A-pillar disposed proximate a forward portion of an occupant compartment and a rearward end of the sport tube extends rearward beyond a C-pillar disposed proximate a rearward portion of the occupant compartment. A side airbag curtain is fixedly coupled with the inboard side of the sport tube, the side airbag curtain having a stowed condition and an inflated condition. A plurality of integrated seal carriers are fixedly coupled with the outboard side of the sport tube and extend laterally outboard of the motor vehicle. Each of the integrated seal carriers comprises a removable roof sealing member defining in part an upwardly facing sealing plane along the longitudinal axis of the motor vehicle for interface with a sealing member on a removable roof and a removable door window seal defining a downwardly facing sealing plane for interface with a retractable door window, wherein the removable roof sealing member and the removable door window seal act independently of each other.

Embodiments of the second aspect of the present disclosure can include any one or a combination of the following features:The plurality of discrete integrated seal carriers are each disposed along a length of the sport tube proximate a location of a retractable window of each of a plurality of removable side doors.The motor vehicle further comprises a vertical B-pillar operably coupled with and at least partially supporting the sport tube disposed between the A-pillar and the C-pillar, and one of the plurality of discrete integrated seal carriers is disposed along a length of the sport tube between the A-pillar and the B-pillar and another of the plurality of discrete integrated seal carriers is disposed along a length of the sport tube between the B-pillar and the C-pillar.The motor vehicle further comprises an external trim cover disposed on one or more of the A-pillar, B-pillar, or the C-pillar, wherein the external trim cover comprises a vertical sealing member defining a longitudinally facing and vertically oriented window sealing plane having an upper end disposed proximate the removable door window seal defining the downwardly facing sealing plane.One of the plurality of external trim covers is disposed on each of the A-pillar, B-pillar, and the C-pillar, and wherein the vertical sealing member of each of the plurality of external trim covers has an upper end disposed proximate the one or the other of the removable door window seal defining the downwardly facing sealing plane.The vertical sealing member of each of the external trim covers defines a longitudinally facing and vertically oriented window sealing plane facing a window opening between the A-pillar and B-pillar or between the B-pillar and the C-pillar.

According to yet another aspect of the present invention, a roof rail assembly for a motor vehicle has an open frame vehicle architecture and comprises an A-pillar disposed proximate a forward portion of an occupant compartment, a C-pillar disposed proximate a rearward portion of the occupant compartment, a B-pillar intermediate the A-pillar and the C-pillar, a cross-member proximate the A-pillar, and a cross-member proximate the C-pillar. The roof rail assembly comprises an elongated hollow sport tube extending along a longitudinal axis of the motor vehicle, the sport tube comprising a two-piece multi-gage tube extending along a longitudinal length of the occupant compartment of the motor vehicle, the sport tube further comprising an inboard side and an outboard side, and a forward end of the sport tube extends from the A-pillar and a rearward end of the sport tube extends rearward beyond a C-pillar. A side airbag curtain is fixedly coupled with the inboard side of the sport tube, the side airbag curtain having a stowed condition and an inflated condition. A plurality of integrated seal carriers are fixedly coupled with the outboard side of the sport tube and extend laterally outboard of the motor vehicle, each of the plurality of the integrated seal carriers comprising a removable roof sealing member defining in part an upwardly facing sealing plane along the longitudinal axis of the motor vehicle for interface with a sealing member on a removable roof and a removable door window seal defining a downwardly facing sealing plane for interface with a retractable door window, wherein the removable roof sealing member and the removable door window seal act independently of each other.

Embodiments of the third aspect of the present disclosure can include any one or a combination of the following features:Each of the integrated seal carriers comprises a vertical flange fixedly coupled with the outboard side of the sport tube and a horizontal flange extending laterally outboard of the motor vehicle upon which removable roof sealing member and the removable door window seal are mounted, wherein a distal outboard edge of the horizontal flange is adapted to resiliently flex upwardly in response to a presence of a fully extended door window in a door-closed position.The removable roof sealing member and the removable door window seal are mounted to the distal outboard edge of the horizontal flange.The sport tube comprises a forward length having a rearward end and a rearward length having a forward end, wherein either of the rearward end of the forward length or the forward end of the rearward length is received within the other to form a tent-poled joint.The tent-poled joint of the sport tube is operably coupled with and supported by the C-pillar.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIG.1, reference numeral10generally designates a motor vehicle. Although illustrated as a six door sport utility type vehicle inFIGS.1and2, the motor vehicle10may be another other type of motor vehicle, such as a two or four door motor vehicle or a van, sedan, or truck, such as the four door sports utility type vehicle shown inFIG.4. The motor vehicle10, as is typical, includes an occupant compartment12within which a plurality of seating assemblies14are mounted. The occupant compartment12is nominally defined by a floor pan16, and, as applicable to the present disclosure, a plurality of removable side door assemblies18and a removable roof assembly20. As shown inFIG.1, and more fully described below, each of the removable side door assemblies18may have a frameless window configuration, whereby the removable side door assemblies18may be removed from the motor vehicle10after the retractable door window22of each has been lowered into the body24of the respective removable side door assembly18.

As schematically shown inFIG.2, with the plurality of removable side door assemblies18and the removable roof assembly20removed, the open frame vehicle architecture of the motor vehicle10is apparent. A driver roof rail assembly26and a passenger roof rail assembly28extend horizontally and parallel to the longitudinal axis of the motor vehicle10along the sides of the motor vehicle10and may be supported by an A-pillar30, B-pillar32, C-pillar34, and D-pillar36, as shown. A forward cross member38and a rearward cross member40may extend between the driver roof rail assembly26and the passenger roof rail assembly28, respectively. The driver roof rail assembly26and the passenger roof rail assembly28are identical mirror images of each other. For purposes of illustrating both, the passenger roof rail assembly28will be more fully described.

As best shown inFIGS.3-5, passenger roof rail assembly28of a four door sports utility type motor vehicle10includes an elongated hollow sport tube42that extends horizontally and parallel to the longitudinal axis of the motor vehicle10. As shown inFIGS.6-7, a side air curtain assembly44and a plurality of integrated seal carriers46may be fixedly coupled to the sport tube42. An interior roof rail trim cover48may also be provided to conceal the side air curtain assembly44, as described below. The sport tube42is essentially the structural support for the passenger roof rail assembly28and may be fabricated from a metal material, such as steel or aluminum.

The sport tube42may comprise a two-piece multi-gage tube extending along a longitudinal length of the occupant compartment12of the motor vehicle10, as shown inFIG.3. That is, the sport tube42may further comprise a forward length50having a rearward end52and a rearward length54having a forward end56. Either of the rearward end52of the forward length50or the forward end56of the rearward length54may be provided with a reduced outer diameter D′ that may be received within an inner diameter D″ of the other to form a tent-poled joint58, as best seen inFIG.9, which shows the forward end56of the rearward length54having a reduced outer diameter D′. The tent-poled joint58may be seam welded, such as via MIG welding60, after assembly. The sport tube42may be hot formed into the configuration of the completed sport tube42shown inFIG.3after the tent-poled joint58is formed.

As shown, the motor vehicle10has an open frame vehicle architecture and comprises the A-pillar30disposed proximate a forward portion of an occupant compartment12, the C-pillar34disposed proximate a rearward portion of the occupant compartment12, the B-pillar32disposed intermediate the A-pillar30and the C-pillar34, the forward cross-member38proximate the A-pillar30, and the rearward cross-member40proximate the C-pillar34. The sport tube42may be fixedly attached to the A-pillar30, B-pillar32, and the C-pillar34via welding techniques and/or via fasteners, as is known, to create a substantially rigid structure partially defining the occupant compartment12.

As shown inFIGS.3and4, the forward length50of the sport tube42extends substantially horizontally and parallel to the longitudinal axis of the motor vehicle10, while the rearward length54of the sport tube42is bent downwardly in the rearward direction at a location rearward of the tent-poled joint58. A rearward end62of the rearward length54of the sport tube42may thus be similarly fixedly attached to the rear body structure64to define the D-pillar36, which together with the rear body structure64may serve to define a rear opening66in the motor vehicle10that may be enclosed with a rear tailgate/retractable door assembly or a hatch assembly (not shown). As perhaps best shown inFIG.8, the tent-poled joint58of the sport tube42may be operably coupled with and directly supported by the C-pillar34, again via welding techniques and/or via fasteners, as is known. This configuration may provide additional structural integrity for the tent-poled joint58.

As shown inFIGS.6and7, the sport tube42may further comprise an inboard side68and an outboard side70, wherein the side air curtain assembly44is fixedly coupled with the inboard side68of the sport tube42and the plurality of integrated seal carriers46are fixedly coupled with the outboard side70of the sport tube42. The side air curtain assembly44extends substantially along the horizontal portion of the longitudinal forward length50of the sport tube42. By virtue of the construction of the sport tube42described above, an angled and smooth inboard side68of the sport tube42is provided by which the side air curtain assembly44may be mounted directly to the sport tube42.

The side air curtain assembly44includes the side air curtain72and an ignitor74, as is known. The side air curtain assembly44has a stowed condition, shown inFIGS.6-7, and an inflated condition, not shown. The side air curtain assembly44may be coupled to the inboard side68of the sport tube42via a plurality of fasteners (not shown) disposed within a plurality of fastener holes extending longitudinally along the passenger roof rail assembly28. In particular, the side air curtain assembly44may be mounted to a uniform and burr free surface with laser cut holes to accommodate rivet nuts. The sport tube42geometry may be designed to optimize the orientation for the side air curtain72to encourage rapid deployment in a desired direction. If desired, the rearward cross-member40proximate the C-pillar34may be used to mount inflating tubes (not shown) for the side air curtain72.

Each of the plurality of integrated seal carriers46is fixedly coupled with the outboard side70of the sport tube42and extend laterally outboard of the motor vehicle10, as shown inFIGS.3,6, and7. Each integrated seal carrier46comprises a removable roof sealing member76defining in part an upwardly facing sealing plane78along the longitudinal axis of the motor vehicle10for interface with a sealing member80on the removable roof assembly20and a removable door window seal82defining a downwardly facing sealing plane84for interface with the retractable door window22of one of the removable side door assemblies18. The removable door window seal82may comprise a single component or a multiple components cooperating to form a seal, as shown.

As shown, the sealing member80on the removable roof assembly20and the removable door window seal82are fabricated from a resilient or elastomeric material, while the removable roof sealing member76is a more rigid material, such as metal. However, the removable roof sealing member76may also include components fabricated from a resilient or elastomeric material. In such case, the sealing member80on the removable roof assembly20may be a more rigid material, such as metal. Finally, both the removable roof sealing member76and the sealing member80on the removable roof assembly20may be fabricated from a resilient or elastomeric material.

As shown inFIGS.3and4, the passenger roof rail assembly28includes the plurality of discrete integrated seal carriers46each disposed along a length of the sport tube42proximate the location of the retractable door window22of each of a plurality of removable side door assemblies18. For example, one of the plurality of discrete integrated seal carriers46may be disposed along a length of the sport tube42between the A-pillar30and the B-pillar32and another of the plurality of discrete integrated seal carriers46may be disposed along a length of the sport tube42between the B-pillar32and the C-pillar34. In effect, each of the integrated seal carriers46is mounted along the sport tube42at a location and having a longitudinal length substantially corresponding to a location and a longitudinal length of the retractable door window22of one of the removable side door assemblies18, respectively.

As best shown inFIGS.6and7, the integrated seal carrier46comprises a vertical flange86fixedly coupled with the outboard side70of the sport tube42and an integrated horizontal flange88extending from the vertical flange86laterally outboard of the motor vehicle10, upon which removable roof sealing member76and the removable door window seal82are mounted. The removable roof sealing member76and the removable door window seal82are mounted to a distal outboard edge90of the horizontal flange88.

As shown inFIGS.6and7, the passenger roof rail assembly28may also include a mounting bracket92fixedly coupled with the distal outboard edge90of the horizontal flange88to which the removable roof sealing member76and the removable door window seal82are resiliently coupled and by which the removable roof sealing member76and the removable door window seal82are supported. As shown, the removable roof sealing member76is formed by an upper apex of the mounting bracket92. The mounting bracket92extends laterally in an outboard direction so as to properly position the removable roof sealing member76and the removable door window seal82for engagement by the sealing member80on the removable roof assembly20and the retractable door window22, respectfully.

Thus positioned, the removable roof sealing member76defines in part the upwardly facing sealing plane78about the upper opening perimeter94of the motor vehicle10for interface with the sealing member80on a perimeter96of the removable roof assembly20. In particular, the removable roof sealing member76, in combination with a ledge98on each of the B-pillar32and C-pillar34, a rearward edge100of a forward transverse body panel102disposed proximate the forward cross-member38proximate the A-pillar30, and a forward edge104of a removable rearward transverse body panel106disposed along the rearward cross-member40proximate the C-pillar34, defines the upwardly facing sealing plane78about the upper opening perimeter94of the motor vehicle10. This upwardly facing sealing plane78is urged into engagement with the sealing member80about a perimeter96of the removable roof assembly20disposed around and under a perimeter edge108of the removable roof assembly20in order to provide a substantially weather-proof interface and reduce wind noise when the removable roof assembly20is installed.

The resulting structure provides a sealing interface between the removable roof assembly20and the passenger roof rail assembly28, while the removable door window seal82provides a sealing interface between an upper edge110of the retractable door window22glass of the removable side door assembly18and the passenger roof rail assembly28. The removable door window seal82, like each of the plurality of integrated seal carriers46, may extend a longitudinal length substantially corresponding to the location and longitudinal length of the retractable door window22of one of the removable side door assemblies18.

The distal outboard edge90of the horizontal flange88may be adapted to resiliently flex upwardly in response to the retractable door window22being raised from a retracted position, as shown inFIG.6, to a fully extended position, as shown inFIG.7, when the removable side door assembly18is in a door-closed position in order to enhance sealing of the upper edge110of the retractable door window22. At the same time, when the removable roof assembly20is installed, as shown inFIG.7, the distal outboard edge90of the horizontal flange88is adapted to resiliently flex downwardly from the condition shownFIG.6in response to the presence of the removable roof assembly20in order to enhance sealing of the perimeter96of the removable roof assembly20. The removable roof sealing member76and the removable door window seal82thus act independently of each other.

The motor vehicle10may also include an external trim cover112disposed on one or more of the A-pillar30, B-pillar32, or the C-pillar34, as shown inFIG.10. A plurality of external trim covers112may be provided, where one of the plurality of external trim covers112is disposed on each of the A-pillar30, B-pillar32, and the C-pillar34. The external trim covers112may be fabricated from a relatively hard polymer, such as polypropylene.

Each of the external trim covers112may include a vertical sealing member114defining a longitudinally facing and vertically oriented window sealing plane116having an upper end118disposed proximate the removable door window seal82defining the downwardly facing sealing plane84. The vertical sealing member114of each of the external trim covers112thus faces the window opening120between the A-pillar30and B-pillar32or between the B-pillar32and the C-pillar34. Thus, the upper edge110and side edges122of the retractable door window22of the removable side door assembly18may be completely, when in the fully raised position, in contact with the removable door window seal82and vertical sealing member114in order to provide a substantially weather-proof interface and reduce wind noise.

The interior roof rail trim cover48may also be provided and likewise fabricated from a relatively hard polymer, such as polypropylene, to allow the side air curtain72of the side air curtain assembly44to deploy in different environmental conditions and temperatures at the lowest economic impact. The passenger roof rail assembly28may also include padding126disposed above an upper edge128of the interior roof rail trim cover48and extending along the longitudinal axis of the motor vehicle10, wherein the padding126may include an energy absorbing material, such as foam.

The interior roof rail trim cover48may be operatively coupled with the sport tube42via a plurality of fasteners (not shown) disposed in a plurality of fastener holes (not shown) proximate the upper edge128of the interior roof rail trim cover48and extending longitudinally along the passenger roof rail assembly28. The interior roof rail trim cover48may also include a cover member130depending from the upper edge128of the interior roof rail trim cover48and extending substantially horizontally and parallel to the longitudinal axis of the motor vehicle10along the horizontal length of the sport tube42.

As shown inFIGS.6-7, the cover member130comprises a lower distal edge132having a longitudinal length that is received within a fastenerless clip134having a longitudinal length disposed below the cover member130and operatively coupled with the passenger roof rail assembly28. The fastenerless clip134may be incorporated as a groove into a separate hard-interior trim base136fixedly coupled with the passenger roof rail assembly28and may be integrally molded therewith. The interior roof rail trim cover48and the hard-interior trim base136of the passenger roof rail assembly28may be formed of a weatherproof material, again such as polypropylene. The lower distal edge132of the cover member130interacting with the fastenerless clip134may include a chamfered surface that is received within the groove disposed on the fastenerless clip134to releasably attach the lower distal edge132to the passenger roof rail assembly28to conceal the side air curtain assembly44in the stowed condition within a space138behind the cover member130. The use of a chamfered surface aids in the release of the lower distal edge132from the fastenerless clip134upon a predetermined force and improve visual appearance.

The cover member130conceals the side air curtain assembly44in the stowed condition within the space138behind the cover member130, as shown inFIGS.6and7. The forces within the space138developed by activation of the side air curtain72from the stowed condition to the inflated condition pushes against an inner surface140of the cover member130and thereby rotates the cover member130about a plurality of parallel hinges142, defined by a plurality of parallel material reduction provided on the inner surface140of the cover member130extending along the longitudinal length of the cover member130, to create an opening to allow passage of side air curtain72out of the passenger roof rail assembly28during activation of the side air curtain72from the stowed condition to the inflated condition.

In summary, the use of a sport tube42presents unique challenges in providing user desired features. The sport tube42described above not only provides a support for a roof structure, but also facilitates the incorporation of additional systems. Package space due to structural requirements, in the past limited for other systems, such as side air curtains72, both hard and soft removable roof sealing, removable door window sealing, and trim components, are accommodated. The multi-functional sport tube42of the present disclosure resolves these package issues with the features mentioned above while providing the necessary roof structure requirements.

The multi-functional sport tube42disclosed herein makes it possible to reliably seal the interior of the occupant compartment12by mounting the removable door window seal82for a frameless retractable side door window22. By mounting the removable door window seal82directly to the sport tube42, variation between the removable roof assembly20and the frameless retractable side door window22is isolated between the two systems, in contrast to motor vehicles that employ framed and unframed doors that seal directly to the removable roof assembly20.

In addition, the presently disclosed sport tube42allows the elimination of a cross-member proximate the B-pillar32, which permits a fuller open air environment when the removable roof assembly20is removed. That is, the canopy of the motor vehicle10may be completely open, while also maintaining structural integrity, in contrast to motor vehicles10that have a cross-member proximate the B-pillar32that blocks upward visibility and limit cabin space.