Protection cushion concealment system for vehicle roll bar assembly

A concealment system for a first vehicle component having a cutout and receiving aperture exposed by removal of a second component, includes a pre-insert configured to be inserted into the receiving aperture, and a filler insert having an outer surface and configured to be inserted into the cutout such that the outer surface of the filler insert is substantially flush with a visible outer surface of the vehicle component. The filler insert being inserted into and retained within the pre-insert.

FIELD

The present application relates generally to convertible top systems for a vehicle and, more particularly, to a concealment system for a protection cushion of a roll bar assembly associated with a vehicle convertible top system.

BACKGROUND

It is known in the motor vehicle art to provide a convertible top, which may be folded back or removed from the vehicle. In one example, the convertible top is constructed of a flexible fabric (referred to as a soft top) and is folded back to a storage position or otherwise removed from an installed position. Soft tops provide a user with the benefit of open air driving while affording available protection in the event of adverse weather conditions. Most known soft tops are designed to be easily retracted to a stored position, either under a source of power or manually. However, portions of a vehicle roll bar assembly or top system may be undesirably exposed once the soft/hard top is removed. Accordingly, while known vehicle top systems work well for their intended purpose, it is desirable to provide an improved vehicle soft top system.

SUMMARY

In accordance with an exemplary aspect of the invention, an insert system for a first vehicle component having a cutout and receiving aperture exposed by removal of a second component from the vehicle is provided. The insert system includes, in one exemplary implementation, a pre-insert configured to be inserted into the receiving aperture, and a filler insert having an outer surface and configured to be inserted into the cutout such that the outer surface of the filler insert is substantially flush with a visible outer surface of the vehicle component. The filler insert is inserted into and retained within the pre-insert.

In addition to the foregoing, the described insert system may include one or more of the following features: wherein the pre-insert includes a main body portion, a plurality of insert retention tabs, and a plurality of retention arms; wherein the main body portion includes a cylindrical wall having an outer surface and an inner surface; wherein each insert retention tab extends outwardly from the main body portion, the retention tabs configured to engage a wall defining the receiving aperture to retain the pre-insert within the first vehicle component; wherein the plurality of insert retention tabs comprises a pair of opposed insert retention tabs; and wherein each retention arm extends inwardly from the main body portion, the retention arms configured to engage the filler insert to retain the filler insert within the pre-insert.

In addition to the foregoing, the described insert system may include one or more of the following features: wherein the plurality of retention arms comprises four equally spaced retention arms; wherein the filler insert includes a base and a shaft extending therefrom; wherein the base is a complementary shape to the cutout; wherein the shaft includes a proximal end and a distal end, the proximal end coupled to the base and the distal end having a substantially spherical shape; and wherein a diameter of the substantially spherical shape is slightly larger than a diameter of the pre-insert such that a force is required for insertion and removal of the shaft from the pre-insert.

In accordance with another exemplary aspect of the invention, a concealment system for a vehicle having a roll bar assembly is provided. The concealment system includes, in one exemplary implementation, a roll bar assembly having a receiving aperture, a first component coupled to the roll bar assembly and having a cutout formed in an outer surface of the first component, the cutout exposed by removal of a second component from the vehicle, wherein the cutout at least partially surrounds the receiving aperture, and an insert system. The insert system includes a pre-insert configured to be inserted into the receiving aperture formed in the roll bar assembly, and a filler insert having an outer surface and a shape complimentary to a shape of the cutout, the filler insert configured to be removably inserted into the cutout and into the pre-insert such that the filler insert is removably retained within the pre-insert and the outer surface is substantially flush with an outer surface of the first vehicle component so as to at least substantially conceal the cutout and the aperture.

In addition to the foregoing, the described vehicle may include one or more of the following features: wherein the first component is an impact cushion and the second component is a door rail removably coupled to the impact cushion and the roll bar assembly; wherein the roll bar assembly includes a main roll bar, a pair of opposed side bars each extending between the main roll bar and a windshield assembly of the vehicle, and a pair of opposed sport bars each extending between the main roll bar and a rear of the vehicle; and wherein the door rail includes a clamp assembly configured to at least partially wrap around the roll bar assembly.

In addition to the foregoing, the described vehicle may include one or more of the following features: wherein the clamp assembly includes an upper clamp portion extending from a main body of the door rail, and a lower clamp portion hingedly coupled to the upper clamp portion, wherein the lower clamp portion is configured to be received in the cutout; wherein the pre-insert includes a main body portion, a plurality of insert retention tabs, and a plurality of retention arms, wherein the main body portion includes a cylindrical wall having an outer surface and an inner surface, wherein each insert retention tab extends outwardly from the main body portion, the retention tabs configured to engage a wall defining the cutout aperture to retain the pre-insert within the first vehicle component, and wherein each retention arm extends inwardly from the main body portion, the retention arms configured to engage the filler insert to retain the filler insert within the pre-insert; and wherein the filler insert includes a base and a shaft extending therefrom.

DESCRIPTION

With initial reference toFIGS. 1-3, an exemplary soft top assembly for a vehicle10is shown and generally identified at reference numeral12.FIGS. 1 and 2illustrate soft top assembly12in a deployed position to protect passengers in the vehicle interior from weather conditions such as wind, rain, or snow. The soft top assembly12can be articulated between its deployed position and a retracted position (not shown). Moreover, soft top assembly12may have one or more intermediate positions to provide varying overhead exposure to the passengers in the vehicle interior, or the soft top assembly12. However, when the soft top assembly12is removed (FIG. 2), for example when utilizing a hard top or power top assemblies, portions of the vehicle10may be exposed and reduce the aesthetic appearance of the vehicle, as described herein in more detail.

In the example implementation shown inFIG. 2, the vehicle10generally includes a vehicle body14, vehicle road wheels16, and front and rear passenger seating (not shown). A roll bar assembly22extends upwardly from the vehicle body14and includes a generally U-shaped main roll bar24formed by a pair of laterally spaced apart vertical members26interconnected by a transverse member28. A pair of rear roll or sport bars30are coupled to the main roll bar24and extend rearward therefrom and downwardly to the vehicle body14. A pair of side bars32are coupled to the main roll bar24and extend forwardly to a vehicle windshield assembly34.

In the example embodiment, a pair of forward door rails36are removably coupled to the main roll bar24and each extends vertically along one vertical member26and laterally along one side bar32. A pair of rearward door rails38each extend vertically between one sport bar30and a rear side panel40of the vehicle body14, and laterally along a portion of the sport bar30.

Although the vehicle10and roll bar assembly22are illustrated inFIG. 2as a four-door configuration, the vehicle may be arranged in other configurations such as a two-door configuration. It will be understood that the soft top assembly for the two-door configuration may include fewer or additional components, but is otherwise generally similar to the soft top assembly12described herein.

With further reference toFIGS. 3 and 4, portions of the roll bar assembly22may include a protecting padding or impact cushion50configured to absorb any impact between the roll bar assembly22and a passenger to facilitate preventing potential injury thereto. In the example embodiment, vehicle10includes four impact cushions50each located along a vehicle interior side of the roll bar assembly22. However, it will be appreciated that roll bar assembly22may have any suitable number of impact cushions50.

In the example embodiment, a first impact cushion50is coupled to an interior side of the passenger side bar32and extends between the main roll bar24and the windshield assembly34(seeFIG. 3). A second impact cushion50is coupled to an interior side of the driver side bar32and extends between the main roll bar24and the windshield assembly34. A third impact cushion50is coupled to an interior side of the vehicle right side sport bar30and extends along at least a portion of the sport bar30. A fourth impact cushion50is coupled to an interior side of the vehicle left side sport bar30and extends along at least a portion of the sport bar30.

As shown inFIG. 3, each impact cushion50includes an upper surface52and an opposed lower surface54(see alsoFIG. 8). The upper surface52includes one or more indentations56disposed adjacent to a fastener aperture58. Each indentation56is configured to provide clearance for a fastener (not shown) to be inserted into fastener aperture58and thereby couple impact cushion50to the roll bar assembly22.

Similarly, the lower surface54includes one or more indentations60having a fastener aperture62(seeFIG. 5). Each indentation60is configured to receive a fastener (not shown) to be inserted into fastener aperture62and thereby further couple impact cushion50to the roll bar assembly22. Further, as shown inFIG. 5, the impact cushion lower surface54also includes one or more cutouts64exposing a receiving aperture66formed in side bar32(or sport bar30). Each cutout64is configured to receive a portion of one of door rails36,38, as is described herein in more detail.

With continued reference toFIG. 2, in the example implementation, each door rail36,38is coupled to the roll bar assembly22by a clamp assembly70. In the illustrated example, each door rail36,38includes two clamp assemblies70. However, each door rail36,38may have any suitable number of clamp assemblies70to facilitate coupling the door rail to the roll bar assembly22. Although there are some structural differences between door rails36and38, clamp assemblies70are substantially similar. One example of door rail36will be described below, however, such description is equally applicable to door rails38.

As shown inFIG. 4, each clamp assembly70includes an upper clamp portion72and a lower clamp portion74. The upper clamp portion72is fixed to a main body76of the door rail36and is configured to rest against an upper surface78(FIG. 3) of the side bar32. The upper clamp portion72includes a bolt end receiving portion80configured to threadably receive a clamp bolt (not shown). The lower clamp portion74is hingedly coupled to the upper clamp portion72and includes an arm82having a bolt aperture84. The arm82is configured to be received within one of the cutouts64of impact cushion50such that bolt aperture84is aligned with receiving aperture66. The clamp bolt is configured to be inserted through apertures66,84and side bar32and into the bolt end receiving portion80to thereby clamp or couple door rail36to side bar32.

When the soft top assembly12is not being utilized, the door rails36,38are removed from the roll bar assembly22. However, as shown inFIG. 5, this causes the cutouts64on the lower surface54of impact cushion50to be exposed to the interior of the vehicle10, which may be unsightly to passengers. Accordingly, vehicle10includes an insert system90configured to be inserted into and conceal the cutout64.

With further reference toFIGS. 5-8, the insert system90generally includes a retention insert or pre-insert92, and an impact cushion insert or filler insert94. Pre-insert92is configured to be inserted into the receiving aperture66disposed within the cutout64, as shown inFIGS. 5 and 8. Filler insert94is configured to be inserted into the pre-insert92such that insert94fills or substantially fills the cutout64and establishes a smooth or continuous lower surface54.

FIGS. 6 and 7illustrate pre-insert92in more detail. In the illustrated embodiment, pre-insert92generally includes a main body portion100, a plurality of retention tabs102, and a plurality of retention arms104.

In the example embodiment, main body portion100includes a cylindrical or substantially cylindrical wall110having an inner surface112and an outer surface114. As shown, main body wall110is discontinuous and includes a first end116and an opposite second end118. Such discontinuity enables the main body portion100to be squeezed or compressed such that first and second ends116,118further overlap, thereby reducing the diameter of cylindrical main body portion100and making it easier to insert pre-insert92into the receiving aperture66. Moreover, once the compressive force is released, the main body wall expands into contact with the walls defining aperture66to facilitate retention of pre-insert92within aperture66and thus roll bar assembly22.

As shown inFIG. 6, each retention tab102includes a leg120having a proximal end122and a distal end124. The proximal end122is coupled to main body cylindrical wall110within a cutaway126formed in the cylindrical wall110, thereby enabling leg120to flex inward and outward without contacting wall110. As illustrated, leg120is angled outwardly from cylindrical wall110as it extends from proximal end122to distal end124, which establishes an interference fit between leg120and the walls defining aperture66to facilitate retention of pre-insert92within aperture66and thus roller bar assembly22. Distal end124includes wings or flanges128configured to abut against the roll bar assembly22when pre-insert92is inserted into aperture66, as shown inFIG. 5. In this way, flanges128facilitate preventing the pre-insert92from being inserted too far into aperture66, while also providing a portion of pre-insert92that can be gripped to flex retention tabs102inward to subsequently remove pre-insert92from within aperture66.

As shown inFIGS. 5 and 6, each retention arm104includes a proximal end130and a distal end132. The proximal end130is coupled to main body cylindrical wall110at an edge134thereof. As illustrated, retention arm104is angled inwardly from cylindrical wall110as it extends from proximal end130to distal end132such that retention arms104are configured to grip or otherwise establish an interference fit with filler insert94when inserted into pre-insert92. Retention arms104are configured to flex outward to receive filler insert94and return inwardly when insert94is removed.

FIGS. 5 and 8illustrate filler insert94in more detail. As described herein, filler insert94is configured to be inserted into and conceal impact cushion cutout64. In the example embodiment, filler insert94generally includes a base140and a shaft142extending therefrom. Base140has a shape complementary to cutout64such that an outer surface144of the base140is flush with or substantially flush with impact cushion lower surface54when filler insert94is inserted into cutout64.

In the example embodiment, shaft142includes a proximal end146and a distal end148. Proximal end146is coupled to base140, and distal end148is generally spherical. However, distal end148may have any suitable shape that enables filler insert94to function as described herein. In the example implementation, the diameter of spherical distal end148is slightly larger than the diameter of aperture66and/or clamp insert main body portion100such that a force is required for insertion and removal of shaft142into/from pre-insert92. This facilitates unintentional removal of filler insert94from within cutout64.

As shown inFIG. 8, roll bar30,32includes a receiving tube150sized to receive clamp insert main body portion100. In this way, retention tabs102extend outwardly against receiving tube150to maintain pre-insert92within aperture66. Shaft proximal end146has a larger diameter sized to be received within main body cylindrical wall110, and shaft distal end148includes a necked down smaller diameter152configured to be contacted by tab retention arms104to further maintain pre-insert92within aperture66. In this way, pre-insert92is securely positioned within aperture66and maintains filler insert94within cutout64to provide an aesthetically pleasing surface when door rails36,38are removed.

Described herein are systems and method for concealing portions of a vehicle roll bar assembly exposed by the removal of components from a removable top system. An insert system includes an initial pre-insert and a subsequent filler insert. A cutout is exposed by the removal of a soft top door rail, and the pre-insert is configured for insertion into an aperture of the roll bar assembly set within the cutout. The filler insert is configured to be removably inserted into the pre-insert and includes a shape complementary to the cutout. As such, once inserted, the filler insert fills the cutout and provides a finished-look surface.