Abstract:
A hardtop convertible roof apparatus is provided. In another aspect of the present invention, rigid, hardtop front and/or rear roof sections are employed. A further aspect of the present invention provides a header latch assembly capable of conveniently and reliably latching the front roof section to a front header. In yet another aspect of the present invention, a panel-to-panel latch assembly is provided that selectively couples the front roof section to the rear roof section in response to the latching of the front roof section to the front header.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Application No. 60/403,701, filed on Aug. 15, 2002. The disclosure of the above application is incorporated herein by reference. 

   BACKGROUND AND SUMMARY OF THE INVENTION 
   This invention relates generally to automotive roof systems and, more particularly, relates to a latching system for retaining a convertible roof apparatus. 
   Rigid hardtop convertible roofs have been used on a variety of automotive vehicles. Some of these conventional convertible hardtop roofs are stored in a generally vertical orientation and some are stored in a predominantly horizontal orientation. Furthermore, some of these conventional hardtop roofs fold in a clam-shelling manner while others are collapsible in an overlapping manner. Examples of traditional hardtop convertible roofs are disclosed in the following patents: U.S. Pat. No. 6,347,828 entitled “Actuation Mechanism for a Two Piece Retractable Hardtop Roof for an Automobile” which issued to Rapin et al. on Feb. 19, 2002; U.S. Pat. No. 6,318,793 entitled “Two Piece Retractable Hardtop Roof for an Automobile” which issued to Rapin et al. on Nov. 20, 2001; U.S. Pat. No. 5,979,970 entitled “Roof Assembly for a Convertible Vehicle” which issued to Rothe et al. on Nov. 9, 1999; U.S. Pat. No. 5,785,375 entitled “Retractable Hardtop for an Automotive Vehicle” which issued to Alexander et al. on Jul. 28, 1998; U.S. Pat. No. 5,769,483 entitled “Convertible Motor Vehicle Roof” which issued to Danzl et al. on Jun. 23, 1998; U.S. Pat. No. 5,743,587 entitled “Apparatus for Use in an Automotive Vehicle having a Convertible Roof System” which issued to Alexander et al. on Apr. 28, 1998; and EPO Patent Publication No. 1 092 580 A1 which was published on Apr. 18, 2001. The U.S. patents are incorporated by reference herein. 
   In accordance with the present invention, a hardtop convertible roof apparatus is provided. In another aspect of the present invention, rigid, hardtop front and/or rear roof sections are employed. A further aspect of the present invention provides a header latch assembly capable of conveniently and reliably latching the front roof section to a front header. In yet another aspect of the present invention, a panel-to-panel latch assembly is provided that selectively couples the front roof section to the rear roof section in response to the latching of the front roof section to the front header. 
   Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
       FIG. 1  is a fragmentary, perspective view, as observed from the rear left corner of the vehicle, showing the preferred embodiment of a hardtop convertible roof apparatus of the present invention disposed in a fully closed and raised position; 
       FIG. 2  is a fragmentary and perspective view, like that of  FIG. 1 , showing the preferred embodiment apparatus disposed in a partially retracted position; 
       FIG. 3  is a fragmentary and perspective view, like that of  FIG. 1 , showing the preferred embodiment apparatus disposed in a fully open and retracted position; 
       FIG. 4  is a centerline cross sectional view showing the preferred embodiment apparatus, disposed in the fully retracted position; 
       FIG. 5  is a side diagrammatic view showing the preferred embodiment apparatus, disposed in the fully closed position; 
       FIG. 6  is a side diagrammatic view showing the preferred embodiment apparatus, disposed in the partially retracted position; 
       FIG. 7  is a side diagrammatic view showing the preferred embodiment apparatus, disposed in the fully retracted position; 
       FIG. 8  is a fragmentary, perspective view, as observed from the front left corner of the vehicle, showing the preferred embodiment of a hardtop convertible roof apparatus of the present invention disposed in a fully closed and raised position; 
       FIG. 9  is a diagrammatic view showing the preferred embodiment drive mechanism; 
       FIG. 10  is a fragmentary and perspective view showing the preferred embodiment apparatus disposed in an unlatched position; 
       FIG. 11  is a diagrammatic view showing the preferred embodiment apparatus disposed in an unlatched position; 
       FIG. 12  is a diagrammatic view showing the preferred embodiment apparatus disposed in an intermediate position; 
       FIG. 13  is a diagrammatic view showing the preferred embodiment apparatus disposed in a latched position; 
       FIG. 14  is a diagrammatic view showing the preferred embodiment apparatus disposed in an unlatched position; and 
       FIG. 15  is a diagrammatic view showing the preferred embodiment apparatus disposed in a latched position. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
   Referring to  FIGS. 1-7 , a convertible roof system  21  is part of an automotive vehicle and includes a hardtop front roof panel  23 , a hardtop rear roof panel  25 , a top stack mechanism  27  operable to move the roofs, a rigid tonneau cover  29  and a tonneau cover mechanism  31 . Roofs  23  and  25  are automatically movable from fully raised and closed positions covering a passenger compartment  33 , as shown in  FIGS. 1 and 5 , to fully retracted and open positions, as shown in  FIGS. 3 ,  4  and  7 , wherein roofs  23  and  25  are stowed in a roof storage area or compartment  35 . Roof storage compartment  35  is located between and physically separated by metal panels  36  (see  FIG. 7 ) from passenger compartment  33  and an externally accessible storage area for miscellaneous articles such as a trunk or pickup truck bed  37 . A rigid, glass back window or backlite  39  is secured to rear roof panel  25  while front roof panel  23  is disengagably attached to a front header panel  41  by latches (to be discussed below). Roofs  23  and  25  are preferably stamped from steel sheets and include inner reinforcement panels, but the roofs may alternately be formed from polymeric composites or aluminum. Roofs  23  and  25  have opaque outside surfaces  43  that are typically painted. These outside surfaces  43  define three-dimensionally curved planes that are stored in a predominantly vertical and parallel nested orientation when fully retracted and stowed; this can be observed best in  FIGS. 4 and 7 . 
   Top stack mechanism  27  is in mirrored symmetry in both outboard sides of the vehicle. Top stack mechanism  27  includes a pair of linkage assemblies  51  and a pair of hydraulic actuators  55 . Linkage assembly  51  is preferably constructed in accordance with German patent application serial number 101 39 354.7 entitled “Carbiolet-Fahrzeug” (Vehicle), which was filed on Aug. 17, 2001. Roofs  23  and  25  can be tightly and closely nested together when fully retracted and the centerline, fore-and-aft roof storage area opening can be minimized due to linkage assemblies  51 . 
   Referring now to  FIGS. 8-15 , convertible roof system  21  further includes a latching system  100  adapted for releasably securing front roof panel  23  to front header panel  41  and, additionally, front roof panel  23  to rear roof panel  25 . Latching system  100  generally includes a drive mechanism  102  centrally disposed within front header panel  41 , a pair of header latch assemblies  104  disposed along outboard portions of front header panel  41 , and a pair of panel-to-panel latch assemblies  106  disposed along the outboard interface of front roof panel  23  and rear roof panel  25 . The pair of header latch assemblies  104  and the pair of panel-to-panel latch assemblies  106  are provided in mirrored symmetry and, thus, in interest the brevity, only one header latch assembly and panel-to-panel latch assembly will be discussed in detail herein. 
   With particular reference to  FIG. 9 , drive mechanism  102  is illustrated in accordance with the principles of the present invention. Drive mechanism  102  generally includes a drive motor  108 , which is operably coupled to a controller  110  via a line  112 . Controller  110  provides a control signal to drive motor  108  to produce a rotary output from drive motor  108  in response to a predetermined condition and/or a user&#39;s actuation of a control switch. Drive motor  108  is operably coupled to a drive plate  114  via a gear interface  116 . However, it should be appreciated that gear interface  116  may include any one of a number of drive transmission systems, such as a worm gear system, planetary gear system, and the like. Preferably, drive motor  108  is coupled to a housing  118 , which is in turn coupled to front header panel  41 . Furthermore, drive plate  114  is rotatably coupled on an opposing side of housing  118  to be easily coupled to the header latch drive rods  120 . Drive plate  114  is adapted to be rotated about its central axis  122  through a predetermined angular path. To prevent excessive rotation of drive plate  114 , drive plate  114  may include at least one stop member  124  extending therefrom that is adapted to engage a corresponding physical stop  126  extending from housing  118 . 
   As indicated above, drive motor  108  and drive plate  114  are adapted to cooperate to drive header latch drive rods  120 . To this end, actuation of drive motor  108  by controller  110  produces an oscillating rotating motion in drive plate  114 . This oscillating rotating motion is transferred to each of the header latch drive rods  120  through a pivoting connection  128 . That is, as drive plate  114  rotates from side to side, this rotating motion is converted into a linear motion through pivoting connection  128  as indicated by the arrows. 
   Referring now to  FIGS. 10-13 , header latch assembly  104  will be described in detail. Specifically, header latch assembly  104  generally includes a striker assembly  130  and a retaining assembly  132 . Striker assembly  130  generally includes a pair of spaced apart plates  134  and  136 . Plates  134  and  136  are generally planar and L-shaped and include a striker member  138  extending therebetween. Header latch assembly  104  further includes a switch actuator  140  extending from a bridge portion  140  formed between plates  134  and  136 . 
   Still referring to  FIGS. 10-13 , retaining assembly  132  generally includes a mounting housing  144 , which is fixedly coupled to front panel header  41  via fasteners extending through mounting holes  146 . As best seen in  FIG. 10 , retaining assembly  130  includes an input stud  148 . Input stud  148  is coupled to an end of header latch drive rod  120  through a connector  150 . Preferably, input stud  148  is a ball stud that is adjustably coupled to threaded connector  150 . Input stud  148  is moved in response to linear motion of header latch drive rod  120  through a path that generally corresponds to arcuate opening  152 . Input stud  148  is fixedly coupled to a first linkage  154  at pivot  156 . First linkage  154  is further pivotally coupled to mounting housing  144  at opposing pivot  158 . 
   First linkage  154  is still further pivotally coupled to second linkage  160  at pivot  156 . An opposing end of second linkage  160  is further pivotally coupled to a midpoint pivot  162  of a third linkage  164 . Third linkage  164  is pivotally coupled at one end to mounting housing  144  at pivot  166  and at an opposing end to a retaining member  168  at cam  170 . 
   Cam  170  includes a cam pin  172 , a first cam slot  174 , and a second cam slot  176 . Cam pin  172  is fixedly coupled through an end of retaining member  168 . A first end of cam pin  172  cammingly engages first cam slot  174 . A second end of cam pin  172  cammingly engages second cam slot  176  formed in housing  144 . Second cam slot  176  is generally angular shaped. 
   Retaining member  168  is generally hook-shaped with a head  178 . Retaining member  168  further includes a third cam slot  180  formed in the body thereof. Third cam slot  180  is adapted to cooperate with a second cam pin  182 , which is fixedly coupled to mounting housing  144 . Head  178  of retaining member  168  is adapted to engage and retain striker member  138  of striker assembly  130  to engage and retaining front roof panel  23  relative to front header panel  41 . 
   Still referring to  FIGS. 10-13 , switch actuator  140  of striker assembly  130  is adapted to be received within a tapered aperture  184  to actuate a closure switch  186 . Closure switch  186  is an electrical switch that is coupled to controller  110  or other logic device via a line  188 . Closure switch  186  includes a movable prong  191 , which is adapted to rotate in response to contact from switch actuator  140 . Tapered aperture  184  is shaped to promote the alignment of switch actuator  140  relative to closure switch  186 . 
   During operation, header latch assembly  104  is actuated to provide a positive and reliable connection between front roof panel  23  and front header panel  41 . To this end, controller  110  outputs a control signal to drive motor  108  in response to actuation of an interior occupant switch and/or closure switch  186 . Drive motor  108  thus drives gear interface  116  to rotate drive plate to  114 . Rotation of drive plate  114  pivots header latch drive rods  120  to produce a linear movement along header latch drive rod  120 . During a locking operation, header latch drive rods  120  produce a pulling force at the end thereof. Accordingly, during an unlocking operation, header latch drive rods  120  produce a pushing force at the end thereof. 
   This pulling force then translates to input stud  148  via header latch drive rod  120 , thereby pulling input stud  148  toward an inboard position of the vehicle, indicated by arrow A (FIG.  10 ). As best seen in  FIGS. 11-13 , this inboard movement of input stud  148  rotates first linkage  154  clockwise about pivot  158 , thereby driving second linkage  160 . Second linkage  160  in turn drives third linkage  164  about pivot  166 . This rotation of third linkage  164  about pivot  166  causes cam pin  172  of retaining member  168  to cam within first slot  174 . Simultaneously, cam pin  172  further cams within second slot  176 . As should be appreciated from  FIGS. 11-13 , second slot  176  generally includes a first arcuate section  190  and a second arcuate section  192 . Movement of cam pin  172  and thus retaining member  168  through first arcuate section  190  of second slot  176  causes retaining member  168  to rotate in a generally circular direction as seen in  FIGS. 11 and 12 . However, movement of cam pin  172  through second arcuate section  192  of second slot  176  causes retaining member  168  to now moved in a generally linear direction as seen in FIG.  13 . This final linear movement aids in pulling front roof panel  23  straight toward front header panel  41  to affect a reliable seal therebetween. Following this final linear movement, front roof panel  23  is now fixedly and reliably secured to front header panel  41 . Unlocking of header latch assembly  104  is achieved through a reverse operation. 
   Referring now to FIGS.  8  and  10 - 15 , panel-to-panel latch assembly  106  is described in detail. Panel-to-panel latch assembly  106  generally includes a roller assembly  200  and a hook assembly  202 . As best seen in  FIGS. 10-13 , roller assembly  200  generally includes a crank  204  that is pivotally coupled between plates  134  and  136  of striker assembly  130  at pivot  206 . Crank  204  includes a bifurcated end portion  208  and a roller portion  210 . During closure of convertible roof system  21 , roller portion  210  is adapted to engage a roller surface  212  formed along a face surface  214  of mounting housing  144 . That is, roller surface  212  generally provides a flat and uniform surface upon which roller portion  210  can roll (see FIGS.  12  and  13 ). Additionally, bifurcated end portion  208  is preferably sized to fit within a corresponding bifurcated end  216  of roller surface  212 . Bifurcated end portion  208  is adapted to engage a pin  218 , which extends between bifurcated ends  216 . More particularly, bifurcated end portion  208  includes an elongated finger  220 , which extends along one side of pin  218 . During an unlocking operation, elongated finger  220  engage pin  208  and ensures that crank  204  begins rotating in a counterclockwise direction as viewed in  FIGS. 11-13 . 
   Roller assembly  200  further includes an extension spring  222  extending between in aperture  224  formed in crank  204  and a mounting post  225 . Mounting post  227  is fixedly coupled between plates  134  and  136 . Extension spring  222  biases crank  204  in a counterclockwise direction as seen in  FIGS. 11-13 . 
   Crank  204  is pivotally coupled to a panel-to-panel latch drive rod  226  at pivot  228 . As best seen in  FIGS. 8 ,  14 , and  15 , panel-to-panel latch drive rod  226  is further pivotally coupled to a latch member  230  of hook assembly  202 . A latch member  230  is pivotally mounted to a bracket  232  at pivot  234 , which is fixed to front roof panel  23 . Latch member  230  is generally U-shaped such that one leg of the U supports the pivot connection between panel-to-panel latch drive rod  226  and latch member  230 . The other leg of the U supports pivot  234  and a hook portion  236 . 
   Hook portion  236  of latch member  230  is adapted to engage a connector  238  to define a locking engagement. Connector  238  is preferably a V-shaped connector when viewed in cross-section. Connector  238  is mounted to a bracket  240 , which is fixed to rear roof panel  25 . 
   Hook assembly  202  further includes an extension spring  242 , which extends between a mounting post  244  extending from bracket  232  and an aperture  246  formed in latch member  230 . Extension spring  242  biases latch member  230  in a counterclockwise direction as seen in  FIGS. 14 and 15 . Accordingly, extension spring  242  cooperates with extension spring  222  to bias panel-to-panel latch assembly  106  into an unlatched position. 
   During operation, panel-to-panel latch assembly  106  is actuated to provide a positive and reliable connection between front roof panel  23  and to rear roof panel  25 . It should be appreciated that the latching and unlatching of panel-to-panel latch assembly  106  is dependent upon the engagement of front roof panel  23  with front header panel  41 . More particularly, as top stack mechanism  27  drives front roof panel  23  toward front header panel  41 , roller  210  engages roller surface  212  on face surface  214 . Further actuation of front roof panel  23  toward front header panel  41  causes roller  210  to roll along roller surface  212 , thereby pivoting crank  204  in a clockwise direction about pivot  206  and against the biasing force of extension spring  222 , as seen in  FIGS. 11-13 . Such rotation of crank  204  about pivot  206  causes a forward linear movement of panel-to-panel latch drive rod  226 . 
   As best seen in  FIGS. 14 and 15 , as top stack mechanism  27  further drives front roof panel  23  and rear roof panel  25  to a closed position, connector  238  travels to a position generally adjacent latch member  230 . The forward linear movement of panel-to-panel latch drive rod  226  pulls upon latch member  230  to rotate latch member  230  about pivot  234  against the biasing force of extension spring  242 . This rotation of latch member  230  causes hook portion  236  to engage connector  238 , thereby fixedly coupling front roof panel  23  and rear roof panel  25 . 
   Although unlocking of panel-to-panel latch assembly  106  is achieved through a reverse operation, it is important to note that finger  220  of crank  204  is adapted to engage pin  218  to ensure that crank  204  is forced to rotated immediately into a counterclockwise direction, while extension springs  222  and  242  further encourage this motion, so as to ensure the proper unlatching of roller assembly  202 . 
   The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.