Retractable roof panel

A vehicle is provided that includes a roof with a roof opening and a rear body portion with a rear opening. Spaced apart guide rails are supported on an exterior surface of the roof. A retractable roof panel is supported on the guide rails by guide members that move along the guide rails along a path. The roof opening and the roof panel extend to the rearward end where the roof panel defines a rear header. The retractable roof panel may be driven from a closed positioned forward to an open position where the roof panel is adjacent to the exterior surface of the roof. The rear gate assembly, which is arranged in the rear opening, may be opened to provide access to the rear cargo area of the vehicle. With the rear gate assembly and retractable roof panel open, large items may be slid into the cargo area and may extend above the plane of the roof.

BACKGROUND OF THE INVENTION

This invention relates to a roof assembly for a vehicle, and more particularly, the invention relates to a retractable roof panel that includes the rear header of the vehicle for providing improved access to the rear cargo area of the vehicle when the roof panel is retracted.

Sunroofs are desireable features to many vehicle customers. Sunroofs are typically arranged in an area above the driver and front passenger seats. The sunroof maybe be retracted to expose the interior of the vehicle to the environment and permit air and light to enter the vehicle. Typically, the opening for the sunroof is relatively small, and sunroofs have not been used to provide increased access to the interior of the vehicle. They have simply been used to provide a more pleasant driving experience to the vehicle occupants.

Once sunroofs are moved from the closed position to an open position, the sunroof is typically stowed in a area between the interior of the roof structure and an interior trim headliner. That is, the sunroof is stowed using the interior space of the vehicle such that it impinges upon the passenger's headroom. The larger the vehicle sunroof, the more problematic it may become to stow the sunroof. Significant vehicle design changes may be required to maintain occupant headroom. As a result, it is desireable to stow a sunroof in the open position in such a manner that interior space is not reduced.

Prior art sunroof assemblies have utilized rails located on the exterior of the roof for storing the sunroof outside of the vehicle. These prior art assemblies have incorporated a roller assembly received in a guide track in the rails. However, the rails lack means to keep debris from entering the guide tracks and inhibiting the operation of the roller assemblies. Even without debris inhibiting the proper operation of the sunroof, the large size of the sunroof makes it difficult for the sunroof to move desirably within the rails without binding.

Therefore, what is needed is a sunroof that does not impinge upon passenger headroom or reduce the interior space in the vehicle. Furthermore, what is needed is a sunroof that provides increased access to the cargo area within the vehicle such that loading and unloading of the vehicle is simplified and larger cargo items may be placed inside the vehicle.

SUMMARY OF THE INVENTION AND ADVANTAGES

The present invention provides a vehicle having a roof with a roof opening and a rear body portion with a rear opening. Spaced apart guide rails are supported on an exterior surface of the roof. A retractable roof panel is supported on the guide rails by guide members that move along the guide rails along a path. The roof opening and the roof panel extend to the rearward end where the roof panel defines a rear header. The retractable roof panel may be driven from a closed position forward to an open position where the roof panel is adjacent to the exterior surface of the roof. The rear gate assembly, which is arranged in the rear opening, may be opened to provide access to the rear cargo area of the vehicle. With the rear gate assembly and retractable roof panel open, large items may be slid into the cargo area and may extend above the plane of the roof.

The guide members move along a path defined by the guide rails. The guide member includes a roller assembly received within a channel in each of the guide rails and a bracket connected to the roller assembly supporting a drive cable. A bracket as supported on the roller assembly and is rotatable relative thereto. The roller assembly includes a flange and the bracket includes a stop of the flange engaging the stop causing the roller assembly and brackets to rotate together. As the roller assembly and its two lower rollers travel along the longitudinal guide rail into the curved portion of the support members connecting the rails to the roof, the roller assembly forces the bracket to rotate with it, which bends the drive cable to prevent it from binding within the support member and rails. The roller assembly may also include a roller biased in an upper direction against a ceiling of the guide rail to vertically locate the sunroof as it moves along the rail and reduce noise and vibration. Seals may be used in the guide rail to seal the drive cable and any wires in a compartment away from debris.

Accordingly, the above invention provides a sunroof that does not impinge upon passenger headroom or reduce the interior space in the vehicle. Furthermore, a sunroof is provided that increases access to the cargo area within the vehicle such that loading and unloading of the vehicle is simplified and larger cargo items may be placed inside the vehicle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A vehicle10utilizing the present invention is shown inFIGS. 1-3. The vehicle10shown has a four-door body12that includes A, B, C, D pillars. The body12has a roof14that includes the present invention retractable roof panel16. The roof panel16has a rear header17, which may commonly be referred to as a D pillar header for the four-door vehicle shown. A wiper19may be mounted to the rear header17.

A rear body portion18defines a rear opening20. A rear gate assembly22is mounted on the rear body portion18to enclose the rear opening20. The gate assembly22may include a frame28supporting a lower body or tail gate26and a window24. However, it is to be understood that any arrangement may be used for the rear gate assembly22. As shown inFIG. 1, the window24may be lowered from an upper boundary21defined by the rear header17into the lower body26to provide partial access to the cargo area30or for manipulating the roof panel16during opening and closing. As shown inFIG. 2, the window and tailgate26may move pivotally upward with the frame28to act as a lift gate. For configurations in which the wiper19is mounted to the rear header17, the window24may be partially opened to ensure clearance of the wiper19. As shown inFIG. 3, the frame28may remain secured to the rear body portion18to manipulate the tail gate26. The window24may be lowered into the tail gate26, and the tail gate may be rotated downward to permit access to the cargo area30of the interior cabin so that objects may be easily slid into the rear of the vehicle. It can be appreciated that the present invention vehicle, as shown inFIGS. 1-3, functions to permit cargo of a relatively limited height to be stored in the cargo area30of the vehicle10.

Referring toFIGS. 4-6, the roof14may be provided by a roof assembly36that may be secured to the rest of the vehicle body during assembly of the vehicle10. The roof assembly36may include all of the features discussed below in addition to other features and interior trim such as head liner and dome lights, etc. The roof assembly36includes the roof14that defines a generally U-shaped roof opening37, best seen in FIG.5. The roof panel16is a rigid unitary structure that is preferably constructed from a fiber reinforced polymer material. The roof14may also be a fiber reinforced polymer material or may be stamped steel. The roof assembly36has a perimeter39of which the rear header17defines the rearward end54of the perimeter39. The roof14includes guide rails40that define a path of the roof panel16. The guide rails40are mounted to the exterior surface38of the roof14. The guide rails include longitudinal members42that are secured to the roof14by support members44. Luggage racks48may be arranged laterally between the guide rails40.

A wind deflector46may be arranged at a forward end47of the roof14to direct wind over the roof panel16when the roof panel16is in the open position, as shown inFIG. 5. Amotor50may be mounted on the exterior surface38of the roof14beneath the wind deflector46. Drive cables52may be coupled to a portion of the roof panel16and connected to the motor50driving the roof panel16between the closed position (shown inFIG. 4) and the open position (shown in FIG.5). The cables52may have a helical outer member typical of the type used in sunroofs.

The roof panel16of the present invention is stowed on the outside of the vehicle10adjacent to the exterior surface38. The forward portion49of the roof panel16may be arranged partially under the wind deflector46with the roof panel16beneath the luggage racks48. Unlike typical sunroof assemblies, the present invention roof panel16moves from the rearward end54of the vehicle to the forward end47of the vehicle. Additionally, the roof panel16includes the rear header17such that when the roof panel16is moved to the open position and the rear gate assembly22is moved to the open position very large items that may extend beyond the plane of the roof14may be placed easily into the cargo area30.

Referring toFIG. 6, the roof panel16is shown supporting the forward portion49in the guide rails40by guide members60. Rear guide member62support the rear of the roof panel16on the roof14, which will be discussed in more detail below. The forward portion of the roof opening37includes a first wall portion64. The forward portion49of the roof panel16includes a second wall portion65that is adjacent to the first wall portion64when the roof panel16is in the closed position. A latch assembly66is mounted underneath the wall portions64and65. The latch may be arranged in any suitable location. The latch assembly66locks the roof panel16to the roof14when the roof is in the closed position. Preferably, two spaced apart latch assembly66are used to reduce the stress on the roof panel16.

Referring toFIGS. 7-9, the forward guide members60are received within the center support members44. The guide members60travel along a path in the longitudinal members42and support members44defined by a channel74. For the embodiment shown, the rear longitudinal members42are for aesthetics and do not support the roof panel16. As shown inFIG. 8, the support member44includes a pocket70received in a recess in the roof14(not shown) and sealed thereto by a gasket72. As the roof panel16moves from the closed position to the open position the guide members60travel up along the channel74defined in the support member44to raise the forward portion49of the roof panel16. The longitudinal42and support44members are secured to one another using a tongue76and groove78arrangement and fasteners (now shown). The drive cables68and wires69may be routed through the channel74and carried by a portion of the guide member60. The wires may be routed to a rear brake light and/or the wiper19.

Referring toFIG. 9, a guide member60includes a cage80that carries a pair of first rollers82rotatable about horizontal axles and second rollers84rotatable about vertical axes. The first rollers82carry the load of the roof panel16on the bottom of the channel74. The second rollers84may ride a long a side of the channel74to take up any lateral clearance and guide the roof in the tracks as it moves between the open and closed positions. However, it is to be understood that any number and configuration of rollers may be used. The cage80includes a lateral member86that extends from the cage80to a block88that is secured to the roof panel16. The lateral member86may include a damper to further minimize roof panel vibrations.

Referring toFIG. 10, a bracket90having a generally vertical elongated aperture92is arranged between the cage80and the roof panel16with the lateral member86disposed within the aperture92. The aperture92permits the rollers82and84and cage80to move upward if the first rollers82must travel over debris trapped on the bottom of the channel74. A biasing member94or spring normally urges the lateral member86downward in the aperture92. Opposing ends95of the spring94are retained with retaining pockets97. The drive cable68and wires69may be respectively mounted on cable96and wire98mounts secured to the bracket90. The motor50pulls the roof panel16forward to the open position. The roof panel16is closed by pushing it and lowering it under the force of its own weight.

A rear guide member62is best shown inFIGS. 11a-11cand12. Unlike the forward guide member60, the rear guide members62do not ride within the guide rails40. However, it is to be understood that the rear guide member62may be configured such that they do ride within the guide rails40similar to the guide members60. The rear guide member62rides along a rear aperture, which may defined by the roof assembly36or another portion of the vehicle10, and a drain trough106which is defined by a channel arranged about the perimeter roof opening37, which is best shown in FIG.12. The rear guide member62includes a bracket108secured to the roof panel16. The bracket108pivotally supports an arm110having rollers112. A spring114biases the arm110forward away from the rear header17. Referring toFIG. 11a, the roof panel16is show in a closed and locked position in which the arm110is tilted rearward with a roller112received in a recess118in the rear aperture104. In this position, the rear of the roof panel16cannot be lifted until the roof panel is moved forward. As the roof panel16is moved forward, as shown inFIG. 11b, the arm110rotates forward as the roof panel16. The spring114urges the arm110to unseat one of the rollers112from the recess118. As the roof panel16continues to move forward, as shown inFIG. 11c, the rollers112move along the drain trough106. The rear guide member62configuration provides enough lift to the rear of the roof panel16such that the roof panel16may clear the exterior surface38of the roof14when in the fully opened position.

In operation, the rear gate assembly22may be manipulated as described in relation toFIGS. 1-3above to permit access to the cargo area30. However, when increased access to the cargo area30is desired, for example for cargo items having a height that exceeds the plane of the roof14, the roof panel16may be retracted. To retract the roof panel16, the latch assembly66must be actuated to unlock the forward portion49of the roof panel16from the roof14. The forward guide member60will begin to move up the channel74in the support member44, and the rear guide member62will rotate forward such that one of the rollers112moves out of engagement with the recess118. The forward guide member60will move along the channels74within the longitudinal member42, and the rear guide member62and will move along the drain trough106. The forward portion49of the roof panel16will preferably be disposed beneath wind deflector46. Preferably when opening the retractable roof panel16, the window24will be lowered into the lower body26to minimize the force on the window24when traveling along a road with the retractable roof panel16in the open position.

FIGS. 13-16are directed to improvements of the guide member60to provide smoother operation of the roof assembly36as it moves along the tracks provided by the guide rails40. The improved guide members60reduces the noise and vibration typically associated with guide members carrying the large weight of the roof assembly in the rails. Referring toFIG. 13, the guide member60is shown arranged within a longitudinal member42of the guide rails40. The guide member60includes a roller assembly81carrying the weight of the roof assembly36within the guide rails40and a bracket90supported by the roller assembly81for transmitting the drive from the drive motor to the roller assembly81for moving the roof assembly between the open and closed positions. The bracket90is disposed within the channel74and has cable96and wire mounts secured to the bracket90by fasteners99. The channel74includes a seal assembly120providing a seal compartment122enclosing the cable96and wire98mounts respectively carrying the drive cable and wires from debris.

A wall124separates the channel74from a second channel126. The roller assembly81is disposed within the second channel126. Elongated slots128are arranged in the channels74for receiving opposing seals130that meet one another at a boundary132. The seals130meet one another at the boundary132but separate from one another to accommodate the bracket90as it moves along the rail40. The seals130may be brushes (FIG. 13A) or rubber wipers (FIG.13). The cable96and wire98mounts have ends that are received within elongated grooves134. The elongated grooves134guide the cable and wire as it moves within a rail specifically, the elongated grooves134are necessary to prevent the cable from buckling as the drive motor drives the cable to push the roof assembly to the closed position.

Referring toFIGS. 13-15, two lower rollers having a horizontal axis of rotation are supported by the cage80of the roller assembly81on a floor136of the rail40. Upper rollers84having a vertical axis of rotation engage the surface of the wall124and may be biased against the wall124by a spring mechanism in the lateral member86. The roof assembly is stabilized by a roller140that is biased in the upper direction along arc C (shown inFIG. 14) against a ceiling138of the rail40. The roller140is supported on an arm142pivotally attached to the cage80. A spring144, which is schematically shown in the figures, urges the arm142and roller140upward. The spring144may be a torsional spring or any suitable spring mechanism known in the art.

As discussed above, it is desirable to utilize elongated grooves134to guide the drive cable as it pushes the roof assembly. However, the guide member60must travel along an arcuate portion in the support members44(best shown inFIG. 8) as the roof assembly moves upward and downward in closed positions. However, the cable does not want to bend in the elongated grooves134and the support members44as the roller assembly81moves along the arcuate portion146. The present invention couples the bracket90to the roller assembly81in such a manner that the bracket90turns with the roller assembly81to bend the cable within the curved elongated grooves134so that it does not bind within the grooves or excessively wear. However, the present invention guide member also is designed such that the roller assembly81can move over debris within the rail40without undesirably rotating the bracket90was moving along a straight groove.

Referring toFIGS. 14-16, the roller assembly81includes a variably opposing flanges148adjacent to the bracket90. The bracket90includes spaced apart upper and lower stops150on each side of the bracket90. A flange148is arranged between each pair of stops150and provides a gap152preferably between the flange and the upper stop to permit upward motion of the roller assembly81as it travels over debris on the floor136of the rail40. The gap permits slight relative rotation between the roller assembly81and the bracket90, approximately 3°. The roller assembly81includes a protruding member154, which may be part of the lateral member86, with a bearing156disposed about the protruding member154. The bearing156is arranged within the aperture92and the bracket90. As the roller assembly81travels along the arcuate portion146. The flange148will engage the stop150and force the bracket90along with the mounts96and98to rotate with the roller assembly81thereby forcing the drive cable to bend as it moves down the arcuate portion146. In this manner, wear caused by the drive cable and cable mounts96and98within the curved elongated grooves134in the support members44is avoided.

The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. The vehicle10includes electronic hardware, software, and actuators typically available. The sequence used to open and close the roof panel16may be programmed and initiated by operation of a switch. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.