Water management systems for vehicle sunroof assemblies

Disclosed are vehicle sunroof assemblies with enhanced water management systems, methods for making/using such sunroof assemblies, and vehicles equipped with sunroof assemblies having sunshade water drainage backup capabilities. A representative sunroof assembly includes a frame that attaches to the body of a motor vehicle, positioned within an aperture in the vehicle's roof structure. A center panel is movably mounted to the frame, and operable to transition between open and closed positions to thereby obstruct and expose the aperture. Also attached to the frame is a drain channel that collects and expels fluids from the sunroof assembly. A sunshade is movably mounted to the frame adjacent the center panel. The sunshade manually or automatically transitions between deployed and stowed positions to thereby prevent and allow the passage of light through the roof's aperture. When in the deployed position, the sunshade repels water and directs the repelled water into the drain channel.

INTRODUCTION

The present disclosure relates generally to compartment closure assemblies for motor vehicles. More specifically, aspects of this disclosure relate to water management systems for sunroof assemblies of motor vehicles.

Most current production motor vehicles, such as the modern-day automobile, are originally equipped with various compartment closure assemblies, namely passenger doors, trunk lids, engine hoods, etc., that are movably mounted to the vehicle body to provide access to the vehicle's various compartments. Some automobiles offer as original or optional equipment a sunroof assembly that is installed within the vehicle roof, e.g., to provide extra sunlight and ventilation for an interior passenger compartment. Vehicle sunroofs may be typified by a motor-driven or manually operated glass pane that slides or pivots to selectively uncover an opening in the roof panel above the passenger compartment. Automotive sunroofs come in many styles, including pop-up designs, slidable varieties, folding configurations, T-top architectures, and panoramic assemblies. To install a sliding sunroof—whether a top load, bottom load, or inbuilt architecture—guide rails are mounted on port and starboard sides of the roof opening, and lateral sides of the glass pane are mated with these guide rails. The perimeter of the sunroof frame may be equipped with a trough that collects and feeds water runoff to one or more bleed nozzles that cooperatively drain water from the frame. Drain hoses may be coupled to the nozzles and fed through structural body pillars to evacuate water from the vehicle.

SUMMARY

Disclosed herein are vehicle sunroof assemblies with enhanced water management systems, methods for making and methods for using such sunroof assemblies, and motor vehicles equipped with a sunroof assembly having a sunshade water drainage backup system. By way of example, there is presented a sunroof water management system that prevents or otherwise mitigates incidental water ingress while the sunroof window is open and the sunshade is drawn closed. The top surface of the sunshade is coated with a suitable hydrophobic or comparably water-repellant treatment. When deployed, the sunshade may take on a convex, pointed, or similar shape designed to direct water runoff to the outer periphery of the sunshade. The sunshade is mounted along the uppermost extent of the sunroof's water trough(s) so as to allow water to naturally flow off the fore, aft and/or lateral edges of the sunshade, e.g., under the force of gravity, into the troughs. An optional pull cup, which is mounted to the leading edge of the sunshade, is fabricated with a drain passage for directing water runoff to the drainage trough. As yet another option, a fluid dam is placed along the trailing edge of the sunshade to guide water runoff, e.g., in one or both transverse directions, into the troughs. Disclosed sunroof water management systems help to repel water and manage accompanying runoff to avoid water entry into the vehicle's interior when the sunroof is left open. This, in turn, will help to reduce warranty claims for interior vehicle water damage caused by water ingress through the sunroof. Another attendant benefit may include the ability to provide additional occupant headroom with the elevated packaging location of the sunshade.

Aspects of this disclosure are directed to vehicle sunroof assemblies with enhanced water management systems. For instance, a sunroof assembly is presented that includes a frame assembly that attaches to the body of a motor vehicle, at least partially nested within an aperture that extends through the vehicle's roof structure. A center panel, which may be in the nature of a glass and/or polymeric pane, is movably mounted to the frame assembly. The center panel pivots and/or slides between a closed position, whereat the center panel substantially or completely obstructs the roof aperture, and an open position, whereat the center panel partly or completely exposes the aperture. A drain channel, which is attached to the frame assembly, collects and expels fluids from the sunroof assembly, e.g., through one or more drain tubes. An opaque or semitransparent sunshade is movably mounted to the frame assembly, adjacent the center panel. This sunshade manually or automatically transitions between a deployed position, whereat the sunshade prevents the passage of light through the roof aperture, and a stowed position, whereat the sunshade allows light to pass through the aperture. When in the deployed position, the sunshade is designed to repel water and direct the repelled water into the drain channel. An upper surface of the sunshade, for example, may be coated with a water-repellant material. In addition, lateral sides of the sunshade may abut top ends of the drain channel's sidewalls to allow water to runoff into the channel.

Other aspects of the present disclosure are directed to motor vehicles that are stock equipped or retrofit with a sunroof assembly having a sunshade water drainage backup system. As used herein, the term “motor vehicle” may include any relevant vehicle platform, such as passenger vehicles (internal combustion engine, hybrid electric, full electric, fuel cell electric, fully or partially autonomous, etc.), commercial vehicles, industrial vehicles, tracked vehicles, off-road and all-terrain vehicles (ATV), farm equipment, boats, etc. In the same vein, the term “sunroof” may be defined herein to include any type of sunroof configuration, including pop-up, sliding, folding, etc. A motor vehicle is presented that includes a vehicle body with a passenger compartment fore or aft of an engine compartment, and roof structure extending above and covering the passenger compartment. Multiple road wheels are rotatably attached to the vehicle body and driven, for example, by an engine and/or an electric motor.

Continuing with the above example, the motor vehicle also includes a sunroof assembly with a frame that is mounted directly or indirectly to the vehicle body, at least partially nested within an aperture in the vehicle's roof structure. A transparent or semitransparent center panel is movably mounted to the sunroof frame, operable to selectively transition between closed and open positions to thereby obstruct and expose the aperture in the roof structure. One or more drain channels, which are attached to the frame assembly (e.g., each integrally formed with or mounted adjacent a discrete window guide rail), collect and expel fluids from the sunroof assembly. A sun-light-blocking sunshade is also movably mounted to the frame assembly, generally parallel to and underneath the center panel. The sunshade is operable to selectively transition between deployed and stowed positions to thereby prevent and allow the passage of light through the roof aperture. This sunshade, when placed in the deployed position, repels water and other fluids, and directs the repelled water into the drain channel for evacuation from the sunroof assembly.

Additional aspects of this disclosure are directed to methods for manufacturing and methods for employing any of the herein depicted or described vehicle sunroof assemblies. For instance, a method is presented for assembling a sunroof assembly for a motor vehicle. The representative method includes, in any order and in any combination with any of the disclosed features and options: attaching a frame assembly to the vehicle body at least partially nested within the aperture in the roof structure; mounting, in a movable manner, a center panel to the frame assembly, the center panel being operable to transition between a closed position, whereat the center panel obstructs the aperture, and an open position, whereat the center panel exposes the aperture; attaching a drain channel to the frame assembly, the drain channel being configured to collect and expel fluids from the sunroof assembly; and mounting, in a movable manner, a sunshade to the frame assembly adjacent the center panel, the sunshade being operable to transition between a deployed position, whereat the sunshade prevents passage of light through the aperture, and a stowed position, whereat the sunshade allows the passage of light through the aperture, wherein the sunshade is configured, when in the deployed position, to repel water and direct the repelled water into the drain channel.

The above summary is not intended to represent every embodiment or every aspect of the present disclosure. Rather, the foregoing summary merely provides an exemplification of some of the novel concepts and features set forth herein. The above features and advantages, and other features and advantages, will be readily apparent from the following detailed description of illustrated embodiments and representative modes for carrying out the disclosure when taken in connection with the accompanying drawings and appended claims. Moreover, this disclosure expressly includes any and all combinations and subcombinations of the elements and features presented above and below.

The present disclosure is amenable to various modifications and alternative forms, and some representative embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the novel aspects of this disclosure are not limited to the particular forms illustrated in the above-enumerated drawings. Rather, the disclosure is to cover all modifications, equivalents, combinations, subcombinations, permutations, groupings, and alternatives falling within the scope of this disclosure as defined by the appended claims.

DETAILED DESCRIPTION

This disclosure is susceptible of embodiment in many different forms. There are shown in the drawings and will herein be described in detail representative embodiments of the disclosure with the understanding that these illustrated examples are provided as an exemplification of the disclosed principles, not limitations of the broad aspects of the disclosure. To that extent, elements and limitations that are described, for example, in the Abstract, Introduction, Summary, and Detailed Description sections, but not explicitly set forth in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference or otherwise.

For purposes of the present detailed description, unless specifically disclaimed: the singular includes the plural and vice versa; the words “and” and “or” shall be both conjunctive and disjunctive; the word “all” means “any and all”; the word “any” means “any and all”; and the words “including” and “comprising” and “having” mean “including without limitation.” Moreover, words of approximation, such as “about,” “almost,” “substantially,” “approximately,” and the like, may be used herein in the sense of “at, near, or nearly at,” or “within 0-5% of,” or “within acceptable manufacturing tolerances,” or any logical combination thereof, for example. Lastly, directional adjectives and adverbs, such as fore, aft, inboard, outboard, starboard, port, vertical, horizontal, upward, downward, front, back, left, right, etc., are with respect to a motor vehicle, namely a forward driving direction of a motor vehicle when the vehicle is operatively oriented on a normal driving surface, for example.

Referring now to the drawings, wherein like reference numbers refer to like features throughout the several views, there is shown inFIG. 1a perspective-view illustration of a representative automobile, which is designated generally at10and portrayed herein for purposes of discussion as a four-door, sedan-style passenger vehicle. Mounted to the vehicle body12of the automobile10, e.g., on a support flange in the vehicle's roof structure14over the passenger compartment16, is a sunroof assembly18. The illustrated automobile10—also referred to herein as “motor vehicle” or “vehicle” for short—is merely an exemplary application with which aspects and features of this disclosure may be practiced. In the same vein, implementation of the present concepts into a motorized “tilt-and-slide” type sunroof assembly18should also be appreciated as an exemplary application of the novel concepts disclosed herein. As such, it will be understood that aspects and features of the present disclosure may be applied to other sunroofs designs, and implemented for any logically relevant type of motor vehicle. Lastly, the drawings presented herein are not necessarily to scale and are provided purely for instructional purposes. Thus, the specific and relative dimensions shown in the drawings are not to be construed as limiting.

Vehicle10ofFIG. 1is erected on a rigid vehicle frame20, either as a body-on-frame or a unibody construction, with an interior passenger compartment16that seats and safeguards the vehicle occupants. A rigid roof structure14generally delimits the upper extent of the passenger compartment16, shielding the driver and passengers from rain, snow and other elements. In accord with the illustrated example, the roof structure14is generally composed of laterally spaced roof rails22that are interconnected with longitudinally spaced crossmember braces (not visible) that cooperatively provide subjacent support for a roof panel24. The roof structure14, including the rails22, braces, and roof panel24, extends over and across the upper extent of the passenger compartment16. Proximate a forward end of the roof structure14is an aperture13that extends through the roof panel24. This aperture13(also referred to herein as “roof aperture”) may be fashioned into the roof structure14by hem flanging the roof panel24over the edge of an inner roof reinforcement panel (not visible). The sunroof assembly18cooperates with the aperture13to allow a vehicle occupant to open and close the aperture13as desired, e.g., for additional sunlight and ventilation. The size, shape and location of the aperture13and, thus, the sunroof assembly18may be modified from that shown in the drawings, e.g., to accommodate the different roof designs of other vehicle platforms.

Turning next toFIG. 2, the vehicle sunroof assembly18is shown constructed as a unitary module that is generally composed of a forward header26, a port-side (first) track28, a starboard-side (second) track30, a rear crossmember32, an underside pan34, a center panel36, and a sunshade38. The header26, tracks28and30, crossmember32and pan34are joined to one another, e.g., via riveting, welding and/or fasteners, to collectively define a generally rectangular sunroof frame assembly40. This frame assembly40functions to operatively attach the sunroof assembly18to the vehicle body12such that the center panel36and a continuous seal42circumscribing the panel36are nested within and coterminous with the roof aperture13. As a non-limiting example, the sunroof frame assembly40may be loaded from inside the passenger compartment16, below the roof rails22and crossmember braces, and then raised into contact with the interior of the roof structure14. Transversely projecting mounting flanges27,31of the tracks28,30are pressed against and fastened via bolts39(FIG. 4) to complementary flanges (not shown) of the roof rails22. Likewise, raised reinforcement ribs35of the forward header26are pressed against and fastened to the underside surfaces of the roof structure's crossmember braces. Adhesives and foam sealants may be applied for a more secure attachment or to ensure a more fluid-tight seal between the frame assembly40and the vehicle roof structure14. Adhesives and/or sealants may also be applied between the sunroof frame assembly rails and endcaps that interface with drain tubes, which are described below. It is envisioned that alternative means and methods may be employed for installing the sunroof assembly18.

Center panel36ofFIG. 2is operatively mounted onto the sunroof frame assembly40such that the center panel36is movable relative to the vehicle roof structure14and aperture13. For a motorized “tilt-and-slide” configuration—an example of which is presented in the drawings—the sunroof assembly18is equipped with a two-way electric stepper motor44that is supported on the forward header26and governed by a programmable electronic control unit (ECU) (not shown). The electric stepper motor44is operatively connected to the center panel36, e.g., via left-hand and right-hand drive arms46and48, respectively, and a drive cable50, to slide the center panel36fore and aft (up and down inFIG. 2) as well as raise and lower the center panel36(out of and into the page inFIG. 2). Port-side and starboard-side tracks28,30, which are generally parallel to each other and the roof rails22, extend between and connect the forward header26to the rear crossmember32. Integrally formed into each track28,30is a respective guide rail29and33, each of which is located adjacent a respective lateral edge11and15of the aperture13in the roof structure14. The center panel36, which may be fabricated from a transparent glass pane, a transparent polymeric sheet, or a laminated glass construction of both, is slidably mounted onto the guide rails29,33via rollers on the drive arms46,48. By operating a switch, dial, softkey, or other suitable input device within the passenger compartment16, a vehicle occupant can activate the stepper motor44and thereby selectively transition the center panel36from a closed position (FIG. 1), whereat the center panel36seats within and substantially or completely obstructs the roof aperture13, to an open position, whereat the center panel36ofFIGS. 1 and 2is slid rearward and/or pivots upward to partly or completely expose the aperture13, and vice versa. Alternative configurations may employ substitute means for moving the center panel, including pneumatic actuators, hydraulic actuators, and manual mechanisms.

With continuing reference to the representative architecture ofFIG. 2, the frame assembly40is equipped with a water management system for regulating and evacuating fluid from the vehicle sunroof assembly18. For instance, one or more fluid conduits, such as drain channel segments60and62ofFIG. 3, as well as drain channel segments64and66ofFIG. 4, may be mounted on, integrally formed with, or otherwise attached to the frame assembly40to collect, e.g., rain water, melting or melted snow, soapy car wash water, etc., and expel the collected liquids from the sunroof assembly18through a series of bleed nozzles52and drain hoses54. According to the illustrated example, two lateral drain channel segments64,66(also referred to herein as “first and second channel segments” for brevity; best seen inFIG. 4) extend in a continuous manner along the fore-aft lengths of the tracks28,30, positioned below respective lateral edges11,15of the roof aperture13. As can be seen inFIG. 4, each channel segment64,66may be integrally formed with a corresponding guide rail29,33and, thus, may be oriented substantially parallel with each other as well as with the rails29,33and the lateral edges of the center panel36. Each channel segment64,66is shown with a U-shaped construction that is formed with a pair of laterally spaced, generally parallel sidewalls65, the bottoms ends of which are interconnected with a base67that extends between and is generally orthogonal to the sidewalls65. A horizontal flange69is integrally formed with and projects inboard from the top end of the innermost sidewall65of each channel segment64,66.

To manage water runoff at forward and rearward ends of the sunroof assembly18, the sunroof water management system may employ a forward drain channel segment60that is attached to the forward header26and, optionally, integrated into a pull cup or handle74. A rearward drain channel segment62may be attached to the frame assembly40underneath the rear crossmember32and sunshade38. By way of non-limiting example, the forward drain channel segment60(or “third channel segment”) may be fabricated as a U-shaped trough that is integrally formed into the top surface of the forward header26, positioned directly underneath the forward-most (fore) edge17of the aperture13. A portion of the forward drain channel segment60may be integrated into the handle74of the sunshade38. Rearward drain channel segment62(or fourth “channel segment”) is shown fabricated as a cup-shaped trough with a serpentine-like transverse cross-section. This channel segment62may be positioned underneath the rearward-most (aft) edge19of the roof aperture13, partially surrounding a roller mechanism70of the sunshade38. The first, second, third and fourth drain channel segments60,62,64and66may be fluidly interconnected, e.g., at intersecting ends thereof proximate the various bleed nozzles52, to form a substantially continuous drain channel that extends around the perimeter of the frame assembly40. It is envisioned that any or all of the drain channel segments60,62,64and66may take on different orientations, locations, and/or structural configurations from that which are shown in the drawings. Moreover, while shown as individual sections that are fluidly connected to form a single, continuous drain channel, it is within the scope of this disclosure to integrally form one or more or all of the channel segments60,62,64and66as a single-piece structure. Optionally, one or more of the channel segments60,62,64and66may be eliminated and/or replaced with alternative structure that diverts fluid into discrete drain channels.

With collective reference now to bothFIGS. 3 and 4, the sunroof assembly18is furnished with a sunshade38that may be manually or electronically operated to selectively prohibit light from entering the passenger compartment16(FIG. 1) through the aperture13in the roof panel24. Put another way, the sunshade38may be drawn across the aperture13from inside of the passenger compartment16such that the sunshade blocks from the sight center panel36. Conversely, the sunshade38may be pulled open, e.g., under the force of a return spring (not visible) or an electric motor, to thereby unblock the aperture13and center panel36such that an occupant may see out of the of the passenger compartment16and, concomitantly, light can enter through the aperture13. In accord with the illustrated example, the sunshade38is a “roll-up” or “roller” type sunshade with an opaque blind72that is attached to a spring-biased roller mechanism70(FIG. 3). The blind72, which may be embodied as a vinyl sheet or other suitable textile material, is movably mounted to the frame assembly40via the roller mechanism70, positioned directly underneath the center panel36(when both are closed). The blind72segment of the sunshade38may be pulled, pushed or otherwise drawn closed to a deployed position (FIG. 4), and thereby substantially or completely prevent light from entering through the aperture13. Conversely, the blind72may be slid open, e.g., under the pull force of a return spring or motor, to a stowed position such that light is allowed to pass through the aperture13. The sunshade38can take on any suitable configuration, including roller type sunshades, as shown, and other available designs, including sliding screen, Roman, etc.

When deployed, the sunshade38is designed to repel liquids and direct the repelled liquids into one or more of the drain channel segments60,62,64,66such that the liquid can be evacuated from the vehicle sunroof assembly18, e.g., through the bleed nozzles52and drain hoses54. In so doing, the sunshade38may function as a “backup” water management system that helps to prevent or otherwise mitigate incidental water ingress and attendant water damage that may occur while the center panel36is open and the sunshade38is deployed. As one option, an upper or topmost surface73(FIG. 3) of the sunshade blind72may be coated with a suitable water-repellant material (e.g., alkyl-based surfactants) or modified with a hydrophobic surface treatment (e.g., cold plasma treatment) to prevent the blind72from absorbing liquids and, at the same time, force the liquids off of the sunshade38. Another option includes the blind72segment of the sunshade38taking on a convex-up shape relative to the roof structure14of the motor vehicle10, as portrayed inFIG. 4. For instance, the blind72may be fabricated with an internal skeletal structure or a exoskeletal backing composed of arc-shaped metallic leaf springs or smart-material based ribs (e.g., electroactive polymers) that flex when the blind72is moved to the deployed position such that the upper surface73rounds and points away from the passenger compartment16(e.g., points upwards inFIG. 4).

Liquids that land on the sunshade38may be routed into one or more of the drain channel segments60,62,64and66by positioning the sunshade blind72along the uppermost extent of each available channel segment60,62,64,66when the sunshade38is deployed. This will allow liquids that fall onto the upper surface73to naturally flow off of the leading, trailing and/or lateral sides of the blind72, e.g., under the force of gravity, into the forward, rearward and/or lateral drain channel segments60,62,64,66. The terms “leading” and “trailing,” as used herein with reference to the sunshade assembly38, may be defined to reference the foremost edge or portion and the rearmost edge or portion, respectively, of the sunshade blind72relative to the blind's direction of travel when the sunshade38transitions from the stowed to the deployed position. Turning again toFIG. 4, opposing first and second lateral sides75and77, respectively, of the sunshade blind72slide across and abut a top end of the inner most sidewall of the first and second channel segments64,66, respectively. Optionally, the first and second lateral sides75,77of the sunshade blind72are shown extending across and wrapping around the flange69and the top end of the inboard sidewall65of their respective channel segments64,66. This will provide a smoother transition for guiding water runoff from the blind72into the first and second channel segments64,66. An optional bead or dovetail slide83may be formed in or attached to each lateral side75,77and mated with a complementary slot in the inboard sidewall65to thereby retain the blind72in constant contact with the channel segments64,66. In the same regard, when the sunshade38is deployed, leading and trailing edges79and81, respectively, of the sunshade blind72are shown positioned above the forward and rearward drain channel segments60,62, as seen inFIG. 3.

The vehicle sunroof assembly18may also incorporate additional features for helping to direct liquids from the sunshade blind72into the drain channel segment(s). One optional feature includes a pull cup or handle74that is mounted proximate the leading edge79of the blind72, and is configured to provide ergonomic gripping hardware for manually opening and closing the sunshade38. This pull cup/handle74is fabricated with a drain passage76(also referred to herein as “transverse drain passage”) that receives water from the upper surface73of the blind72, and directs the received water into one or more of the drain channel segments64,66. To assist with draining water from the leading edge79of the sunshade38, the blind72may be angled with respect to the roof structure14, as shown inFIG. 3, such that the leading edge79is lower than the trailing edge81, e.g., whereby water is directed towards the drain passage76in the pull cup/handle74. For at least some embodiments, this drain passage76extends transversely along the leading edge79to opposite edges at both lateral sides75,77of the sunshade blind72. As another optional feature, a fluid dam or wiper blade78may be mounted, e.g., to the rear crossmember32or other suitable structure, proximate the trailing edge81of the blind72. This fluid dam/wiper blade78is shaped and positioned to redirect water from the upper surface73of the sunshade blind72into one or more of the drain channel segments64,66.