Abstract:
In an embodiment, the presently disclosed method for coupling a sunroof assembly to a structural frame of a vehicle includes the following steps: (a) moving a sunroof module and a bond frame of the sunroof assembly through a windshield opening of the structural frame and toward a roof portion of the structural frame; (b) securing the sunroof module to the roof portion of the structural frame; (c) moving a locating fixture downwardly toward the roof portion of the structural frame; (d) inserting the frame pins of the locating fixture in frame pockets of the structural frame; (e) applying a first clamping force to the structural frame and the locating fixture; (f) inserting the sunroof pins of the locating fixture in the sunroof pockets of the bond frame; (g) applying a second clamping force to the bond frame; and (h) securing the bond frame to the sunroof module.

Description:
TECHNICAL FIELD 
     The present disclosure relates to a method for coupling a sunroof assembly to a structural frame of a vehicle. 
     BACKGROUND 
     Some vehicles are designed with a sunroof cooperating with a passenger compartment. Generally, the sunroof includes a glass component that is movable to selectively uncover an opening in the roof of the vehicle. To attach the sunroof to the vehicle, whether in a top load operation or a bottom load operation, the entire sunroof, including a frame and the glass component, are installed in the vehicle as a single unit. 
     SUMMARY 
     It is useful to develop a method for coupling a sunroof glass apparatus to a structural frame of a vehicle, wherein the sunroof glass apparatus is larger than the sunroof aperture formed in the roof portion of the structural frame. Instead of installing the entire sunroof assembly, including a frame and a glass component, in the structural frame as a single unit, it is useful to develop a method for coupling a sunroof frame to the bottom of the roof portion of the structural frame and then installing the sunroof glass apparatus from the top of the structural frame of the vehicle. The presently disclosed method allows the coupling of a sunroof glass from above the top of the vehicle (i.e., top loading) to a sunroof assembly that was previously loaded from the underside of the vehicle roof (i.e., bottom load). This method not only enables the attachment of a sunroof glass that is larger than the sunroof aperture to the sunroof assembly but also allows the bond frame of the sunroof assembly to be located in a dimensionally precise manner relative to the structural frame of the vehicle. 
     In an embodiment, the presently disclosed method for coupling a sunroof assembly to a structural frame of a vehicle includes the following steps: (a) moving a sunroof module and a bond frame of the sunroof assembly through a windshield opening of the structural frame and toward a roof portion of the structural frame, wherein the structural frame has a plurality of frame pockets, and the bond frame has a plurality of sunroof pockets; (b) securing the sunroof module to the roof portion of the structural frame in order to fix a position of the sunroof module relative to the structural frame; (c) moving a locating fixture downwardly toward the roof portion of the structural frame, wherein the locating fixture includes a fixture frame, frame pins coupled to the fixture frame, and sunroof pins coupled to the fixture frame; (d) inserting the frame pins in the frame pockets of the structural frame in order to locate the locating fixture relative to the structural frame along a fore-aft direction; (e) applying a first clamping force to the structural frame and the locating fixture in order to fix a position of the locating fixture relative to the structural frame; (f) inserting the sunroof pins of the locating fixture in the sunroof pockets of the bond frame in order to locate the bond frame relative to the locating fixture; (g) applying a second clamping force to the bond frame in order to fix a position of the bond frame relative to the locating fixture; and (h) securing the bond frame to the sunroof module in order to fix a position of the bond frame relative to the sunroof module. 
     In another embodiment, the method includes the following steps: (a) securing a sunroof module of the sunroof assembly to a roof portion of the structural frame in order to fix a position of the sunroof module relative to the structural frame while a bond frame of the sunroof assembly is at least partially disposed in a sunroof opening of the structural frame, wherein the structural frame has a plurality of frame pockets, and the bond frame has sunroof pockets; (b) moving a locating fixture downwardly toward the roof portion of the structural frame, wherein the locating fixture includes a fixture frame, frame pins coupled to the fixture frame, and sunroof pins coupled to the fixture frame; (c) inserting the frame pins in the frame pockets of the structural frame in order to locate the locating fixture relative to the structural frame along a fore-aft direction; (d) applying a first clamping force to the structural frame and the locating fixture in order to fix a position of the locating fixture relative to the structural frame; (e) inserting the sunroof pins of the locating fixture in the sunroof pockets of the bond frame in order to locate the bond frame relative to the locating fixture; (f) applying a second clamping force to the bond frame in order to fix a position of the bond frame relative to the locating fixture; and (g) securing the bond frame to the sunroof module in order to fix a position of the bond frame relative to the sunroof module. 
     The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the teachings when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of a vehicle including a sunroof assembly. 
         FIG. 2  is a schematic fragmentary perspective view of the vehicle, showing the glass apparatus of the sunroof assembly in an open position. 
         FIG. 3  is a schematic fragmentary perspective view of a structural frame of the vehicle and a sunroof module being loaded through the windshield opening of the structural frame. 
         FIG. 4  is a schematic fragmentary cross-sectional view of the structural frame and the sunroof module coupled to the structural frame. 
         FIG. 5  is a schematic fragmentary top view of a locating fixture over the structural frame of the vehicle. 
         FIG. 6  is a schematic fragmentary cross-sectional view of a locating fixture on top of the structural frame of the vehicle, taken along section line  6 - 6  of  FIG. 5 . 
         FIG. 7  is a schematic fragmentary top view of the structural frame and a bond frame of the sunroof assembly. 
         FIG. 8  is a schematic fragmentary cross-sectional view of the structural frame and the sunroof pins and sunroof pads of the locating fixture moving toward the structural frame, taken along section line  8 - 8  of  FIG. 7 . 
         FIG. 9  is a schematic fragmentary cross-sectional view of the structural frame and the locating fixture being clamped together. 
         FIG. 10  is a schematic fragmentary cross-sectional view of the sunroof module being coupled to the structural frame. 
     
    
    
     DETAILED DESCRIPTION 
     Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “up”, “downward”, “down”, “top”, “bottom”, “left”, “right”, “back”, “forth”, etc., are used descriptively for the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Furthermore, the term “substantially” can refer to a slight imprecision or slight variance of a condition, quantity, value, or dimension, etc., some of which that are within manufacturing variance or tolerance ranges that can be subject to human error during installation. 
     Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a vehicle  10  is generally shown in  FIG. 1 . The vehicle  10  can be an automotive vehicle, such as, a car, a truck, a sport utility vehicle (SUV), etc. It is to be appreciated that the vehicle  10  can alternatively be a non-automotive vehicle. 
     As best shown in  FIG. 3 , the vehicle  10  includes a structural frame  12  having a roof portion  14 . The roof portion  14  can include a first roof rail  18  and a second roof rail  20  spaced from each other along a lateral direction indicated by double arrows L (i.e., the cross-car direction). The structural frame  12  can also include A-pillars  22 . The structural frame  12  can include one or more braces  36  attached to the first roof rail  18  and the second roof rail  20  to support the sides of the structural frame  12 . Further, the structural frame  12  defines a windshield opening  23  between the two A-pillars  22 . The windshield opening  23  is configured, shaped, and sized to receive the windshield  38  ( FIG. 1 ) of the vehicle  10 . In the depicted embodiment, two A-pillars  22  and at least one brace  36  partially define the windshield opening  23 . Furthermore, two braces  36  and the roof rails  18 ,  20  together define a sunroof opening  21 . 
     With reference again to  FIG. 1 , the vehicle  10  can include a windshield  38  generally disposed between the A-pillars  22 . In particular, the windshield  38  is disposed in the windshield opening  23 . In the depicted embodiment, the vehicle  10  has a passenger compartment  16  and one or more doors  35  that provide access to the passenger compartment  16 . The doors  35  are movable relative to the structural frame  12  ( FIG. 2 ). 
     The vehicle  10  further includes a roof panel  42  attached to the roof portion  14  ( FIG. 2 ) of the structural frame  12 . Specifically, the roof panel  42  is attached to the first and second roof rails  18 ,  20  on each side of the vehicle  10 . The roof panel  42  further encloses the passenger compartment  16  along the roof portion  14 . 
     With reference to  FIG. 2 , the roof panel  42  defines an aperture  44 . The vehicle  10  can also include a sunroof assembly  48  that cooperates with the roof panel  42 . Specifically, the sunroof assembly  48  cooperates with the aperture  44  to allow a passenger inside the vehicle  10  to open and close the aperture  44  as desired. It is to be appreciated that the configuration of the sunroof assembly  48  can change to cooperate with roof panels  42  of different configurations. Specifically, the sunroof assembly  48  includes a glass apparatus  60  movable relative to the structural frame  12  between a closed position ( FIG. 1 ) and an open position ( FIG. 2 ). The glass apparatus  60  can be movable automatically or manually. In certain embodiments, a switch or button is depressed to actuate the mechanism (not shown) that moves the glass apparatus  60 . 
     The glass apparatus  60  can include a laminated-vitreous element  88 . The laminated-vitreous element  88  can be, for example, laminated glass, polycarbonate, or any other suitable material. The laminated-vitreous element  88  can present a clear appearance or a shaded/tinted appearance. For example, the laminated-vitreous element  88  can be a translucent color (black tint, brown tint, blue tint, etc.) or be transparent/clear (no tint). The glass apparatus  60  is movable relative to the structural frame  12 . The vehicle  10  may include a stationary glass apparatus  19  that remains stationary relative to the structural frame  12 . 
     With reference to  FIGS. 3 and 4 , the sunroof assembly  48  includes a sunroof module  58  and a bond frame  29 . The sunroof module  58  can be attached to the structural frame  12 , and the bond frame  29  can be attached to the sunroof module  58 . The bond frame  29  can be disposed between two braces  36  and the first and second roof rails  18 ,  20 . Further, the bond frame  29  defines the aperture  44 . The bond frame  29  can support the glass apparatus  60 . 
     The sunroof module  58  may have a substantially rectangular shape and defines at least one module opening  61 . In the depicted embodiment, the sunroof module  58  includes a bracket  59  separating two module openings  61 . The sunroof module  58  defines a plurality of fastener holes  63  each configured, shaped, and sized to receive a fastener  65 , such as a screw or a bolt. The structural frame  12  also defines frame holes  13  configured, shaped, and sized to receive a fastener  65 . In the depicted embodiment, the sunroof module  58  has eight (8) fastener holes  63 , and the structural frame  12  also has eight (8) frame holes  13 . However, the sunroof module  58  may have more or fewer fastener holes  63 , and the structural frame  12  may have more or fewer frame holes  13 . 
     The present disclosure relates to a method for coupling the sunroof assembly  48  to the structural frame  12 . In particular, the presently disclosed method facilitates locating the bond frame  29  relative to the sunroof module  58  and the structural frame  12 . As shown in  FIG. 2 , the presently disclosed method begins by loading the sunroof module  58  and the bond frame  29  into the structural frame  12  through the windshield opening  23 . To do so, the sunroof module  58  and the bond frame  29  are moved toward the structural frame  12  in the direction indicated by arrow A. The sunroof module  58  and the bond frame  29  should be moved toward the structural frame  12  until the fastener holes  63  of the sunroof module  58  are substantially aligned with the frame holes  13  of the structural frame  12  (as shown in  FIG. 4 ) in order to allow a fastener  65  ( FIG. 4 ) to be inserted through a fastener hole  63  and a frame hole  13 . At this point, the sunroof module  58  and the bond frame  29  are at least partially disposed in or underneath the sunroof opening  21 . Thus, the sunroof opening  21  is configured, shaped, and sized to at least partly receive the bond frame  29 . In turn, the bond frame  29  defines a bond frame opening  31 . 
     With reference to  FIG. 4 , after substantially aligning the frame holes  13  of the structural frame  12  with the fastener holes  63  of the sunroof module  58 , fasteners  65  are inserted through the frame holes  13  and the fastener holes  63  in order to secure the sunroof module  58  to the structural frame  12 . The fasteners  65  may be bolts, screws, or any other fastener suitable for coupling the sunroof module  58  to the structural frame  12 . 
     With reference to  FIGS. 5 and 6 , a locating fixture  100  is lowered onto the roof portion  14  of the structural frame  12  from a position above the structural frame  12 . The locating fixture  100  includes a fixture frame  102 . The fixture frame  102  includes a plurality of fixture bars  104  coupled to one another. In addition, the locating fixture  100  includes a plurality of frame pins  106  ( FIG. 6 ) protruding downwardly from the fixture frame  102 . The frame pins  106  are coupled to the fixture frame  102  and, therefore, can move along with the fixture frame  102  in a vertical direction indicated by double arrows U ( FIG. 6 ). The frame pins  106  are configured, shaped, and sized to be disposed in the frame pockets  108 A,  108 B of the structural frame  12  in order to align the locating fixture  100  along the fore-aft direction indicated by double arrows F. Each of the frame pockets  108 A,  108 B are configured, sized, and shaped to receive one of the frame pins  106  of the locating fixture  100  in order to locate the locating fixture  100  relative to the structural frame  12  along the vehicle center line C (i.e., along the fore-aft direction indicated by double arrows F). The frame pockets  108 A,  108 B may be configured as holes, slots, or any suitable opening capable of receiving the frame pins  106 . Regardless of their configuration, the frame pockets  108 A,  108 A are disposed in the roof portion  14  of the structural frame  12 . In the depicted embodiment, the frame pockets  108 A,  108 B are formed in the brace  36  that is closest to the windshield opening  23 . However, it is contemplated that the frame pockets  108 A,  108 B may be in other parts of the roof portion  14 . Irrespective of their specific location in the structural frame  12 , the frame pockets  108 A,  108 B are spaced apart from each other along a lateral direction indicted by double arrows L and serve as fore-aft datum targets for the frame pins  106  as discussed in detail below. The lateral direction indicated by arrow L may also be referred to as a cross-car direction. The lateral direction indicated by double arrows L is substantially perpendicular to the fore-aft direction indicated by double arrows F and the vehicle center line C. In the depicted embodiment, the structural frame  12  has two of the frame pockets  108 A,  108 B, and the locating fixture  100  includes two of the frame pins  106 . However, the structural frame  12  may have more than two of the frame pockets  108 A,  108 B, and the locating fixture  100  may include more than two of the frame pins  106 . 
     Aside from the frame pins  106 , the locating fixture  100  includes a plurality of frame pads  110  coupled to the fixture frame  102 . The frame pads  110  serve as locators in order to locate the locating fixture  100  relative to the structural frame  12  along the vertical direction (up/down directions) as indicated by double arrows U ( FIG. 6 ). Because the frame pads  110  are coupled to the fixture frame  102 , the frame pads  110  can also move along the vertical direction indicated by double arrows U ( FIG. 6 ). In the depicted embodiment, the locating fixture  100  includes four of the frame pads  110  coupled to the fixture frame  102 . However, it is contemplated that the locating fixture  100  may include more or fewer of the frame pads  110 . 
     With continued reference to  FIGS. 5 and 6 , the locating fixture  100  is lowered onto the roof portion  14  of the structural frame  12  from a position above the structural frame  12 . As the locating fixture  100  is lowered, the frame pins  106  and the frame pads  110  move downwardly toward the roof portion  14  of the structural frame  12  in the direction indicated by arrows D. The frame pins  106  and the frame pads  110  can move simultaneously toward the structural frame  12 . The locating fixture  100  should be moved toward the roof portion  14  until the frame pins  106  are disposed inside the frame pockets  108 A,  108 B and the frame pads  110  are disposed on the roof portion  14  of the structural frame  12 . 
     Before, after, or while inserting the frame pins  106  in the frame pockets  108 A,  108 B and placing the frame pads  110  on top of the roof portion  14 , the locating fixture  100  is centered along the vehicle center line C. A centering device  200  can be used to center the locating fixture  100  along the vehicle center line C. Specifically, the centering device  200  includes a device body  202  and at least two legs  204  extending from the device body  202 . The legs  204  of the centering device  200  can push the sides of the structural frame  12  in order to align the locating fixture  100  along the vehicle center line C. In other words, the centering device  200  can push against the sides of the structural frame  12  in order to center the locating fixture  100  in relation to the structural frame  12 . 
     After centering the locating fixture  100  and inserting the frame pins  106  in the frame pockets  108 A,  108 B, the locating fixture  100  is secured to the structural frame  12 . To do so, a clamping force B 1  can be applied to the structural frame  12  and the locating fixture  100  in order to fix the position of the locating fixture  100  relative to the structural frame  12 . A clamp can be used to apply the clamping force B 1  to the locating fixture  100  and the structural frame  12 . The clamping force B 1  may be referred to as the first clamping force. 
     With reference to  FIGS. 7 and 8 , after the locating fixture  100  is secured to the structural frame  12 , the locating fixture  100  locates the bond frame  29  relative to the structural frame  12 . The bond frame  29  defines a plurality of sunroof pockets  33 A,  33 B, and the locating fixture  100  includes a plurality of sunroof pins  112  configured, shaped, and sized to be received in the sunroof pockets  33 A,  33 B. In the depicted embodiment, the bond frame  29  has two sunroof pockets  33 A,  33 B, and the structural frame  12  has two sunroof pins  112 . However, it is contemplated that the bond frame  29  may have more sunroof pockets  33 A,  33 B, and the structural frame  12  may have more sunroof pins  112 . Regardless of the quantity, each sunroof pocket  33 A,  33 B is configured, shaped, and sized to receive one of the sunroof pins  112  of the locating fixture  100 . Further, the sunroof pockets  33 A,  33 B are spaced apart from each other along the lateral direction indicated by double arrows L and the fore-aft direction indicated by double arrows F. Moreover, the sunroof pockets  33 A,  33 B serve as cross-car and fore-aft datum targets for the sunroof pins  112  of the locating fixture  100  as discussed in detail below. The bond frame  29  may include additional sunroof pockets  33 C and  33 D to locate the glass apparatus  60  relative to the bond frame  29  until an adhesive used to bond the bond frame  29  to the glass apparatus  60  cures. 
     The locating fixture  100  also has sunroof pads  114  configured to be placed on the bond frame  29  at locations R 1 , R 2 , R 3 , and R 4  ( FIG. 6 ) as discussed in detail below. The sunroof pads  114  can be movably coupled to the fixture frame  102 . The locations R 1 , R 2 , R 3 , and R 4  of the bond frame  29  are up/down datum targets for the sunroof pads  114  of the locating fixture. The sunroof pads  114  of the locating fixture  100  are used to locate the bond frame  29  relative to the sunroof module  58  and the structural frame  12  as discussed below. 
     In the presently disclosed method, the sunroof pins  112  and the sunroof pads  114  move downwardly toward the bond frame  29  in the direction indicated by arrows D as shown in  FIG. 8 . The sunroof pins  112  can be movably coupled to the fixture frame  102 . The locating fixture  100  should be moved toward the bond frame  29  until the sunroof pins  112  of the locating fixture  100  are disposed inside the sunroof pockets  33 A,  33 B and the sunroof pads  114  are disposed over the bond frame  29 . In particular, the sunroof pads  114  are moved toward the bond frame  29  until the sunroof pads  114  are located over the bond frame  29  at locations R 1 , R 2 , R 3 , and R 3 . At this juncture, the sunroof pads  114  are not necessarily contacting the bond frame  29 . The sunroof pins  112  and the sunroof pads  114  can move simultaneously toward the bond frame  29 . 
     Next, with specific reference to  FIG. 9 , a clamping force B 2  can be applied to the bond frame  29  and the locating fixture  100  in order to move the bond frame  29  toward the sunroof pads  114  and fix the position of the locating fixture  100  relative to the bond frame  29 . At this juncture, the sunroof pads  114  can contact the bond frame  29  at the locations R 1 , R 2 , R 3 , and R 4 . A clamp can be used to apply the clamping force B 2  to the locating fixture  100  and the bond frame  29 . The clamping force B 2  may be referred to as the second clamping force. 
     With reference to  FIG. 10 , the bond frame  29  can be secured to the sunroof module  58  while the sunroof pads  114  are contacting the bond frame  28 , the sunroof pins  112  are disposed inside the sunroof pockets  33 A,  33 B,  33 C,  33 D and the clamping force B 2  is being applied to the bond frame  29 . The bond frame  29  can be secured to the sunroof module  58  with fasteners  65 , such as screws and bolts. For example, the fasteners  65  can be inserted through the sunroof module  58  and the bond frame  29  at opposite sides of the bond frame  29  in order to secure the bond frame  29  to the sunroof module  58 . The fasteners  65  can be advanced toward the bond frame  29  in the direction indicated by arrow S. After the sunroof module  58  is secured to the bond frame  29 , the locating fixture  100  can be withdrawn from the bond frame  29 . Specifically, the locating fixture  100  (along with the sunroof pads  114  and the sunroof pins  112 ) can be moved away from the bond frame  29  after the clamping forces B 1 , B 2  have been released from the bond frame  29  and the structural frame  12 . The glass apparatus  60  ( FIG. 1 ) can then be lowered toward the roof portion  14  of the structural frame  12  and coupled to the sunroof module  58 . 
     While the best modes for carrying out the disclosure have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the disclosure within the scope of the appended claims. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.