Abstract:
A canopy top for a utility or recreational vehicle having improved drainage. The canopy has a gutter extending along a portion of its top surface and a drain hole extending through the canopy. The drain hole has a given configuration with a receiving edge extending along the gutter&#39;s collection surface. The receiving edge has a length equal to or greater than a maximum height, taken substantially perpendicular to the receiving edge, of the hole. The hole also has an exit edge extending along the bottom surface and the receiving and exit ledges are tapered toward one another and joined by an arcuate transition portion.

Description:
[0001]    This application claims priority from U.S. patent application No. 09/439,149 filed Nov. 12, 1999, now U.S. Pat. No. 6,186,584, issued Feb. 13, 2001. 
     
    
     
       BACKGROUND  
         [0002]    The present invention relates to recreational and utility vehicles, and more particularly to canopy tops for golf cars and similar utility vehicles.  
           [0003]    Golf cars, and similar recreational or utility vehicles, often include a roof in the form of a canopy over at least the passenger sitting area to protect the passengers from sun and rain. Some prior art canopies have been constructed from single or multiple sheets of thermoplastic material, such as polyethylene or polypropylene. Many prior art canopies constructed from a single sheet of thermoplastic material lack rigidity and are subject to vibration and early failure. On the other hand, many prior art canopies constructed from multiple sheets of thermoplastic material are unacceptably heavy or bulky in appearance. In both cases, prior art canopies generally have a sharp edge along the perimeter against which a passenger&#39;s head might strike, causing injury. Additionally, many prior art canopies are subject to water dripping from the canopy into the vehicle.  
         SUMMARY  
         [0004]    The present invention relates to a canopy top for a utility or recreational vehicle having improved drainage.  
           [0005]    In one aspect of the present invention, the canopy has a gutter extending along a portion of its top surface and a drain hole extending through the canopy. The drain hole has a given configuration with a receiving edge extending along the gutter&#39;s collection surface. The receiving edge has a length equal to or greater than a maximum height, taken substantially perpendicular to the receiving edge, of the hole. In a second aspect of the invention, the hole also has an exit edge extending along the bottom surface and a directing ledge protruding from the bottom surface and extending between the exit edge and the perimeter edge of the canopy. In another aspect of the invention, the receiving and exit ledges are tapered toward one another and joined by an arcuate transition portion.  
           [0006]    In yet another aspect of the invention, the canopy has a drip bead depending from its bottom surface about a substantial portion of its perimeter edge. The drip bead has opposed inner and outer sides joined by a tip terminating in a minimized surface area. At least the inner side is substantially perpendicular to the bottom surface of the canopy. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a schematic, perspective front view of a golf car incorporating features of the invention;  
         [0008]    [0008]FIG. 2 is a schematic, perspective front view of a sunroof canopy, with mounting frames and braces, and exploded, magnified portions illustrating mounting of the canopy to a golf car;  
         [0009]    [0009]FIG. 3 is a schematic, top plan view of the canopy of FIG. 1;  
         [0010]    [0010]FIG. 4 is a schematic, bottom plan view of the canopy of FIG. 1 with the stiffener channels shown in dotted lines;  
         [0011]    [0011]FIG. 5 is a cross-sectional view along line  5 - 5  in FIG. 4;  
         [0012]    [0012]FIG. 6 is a cross-sectional view along line  6 - 6  in FIG. 4;  
         [0013]    [0013]FIG. 7 is a cross-sectional view along line  7 - 7  in FIG. 3;  
         [0014]    [0014]FIG. 8 is a perspective rear view of the underside of the canopy of FIG. 1;  
         [0015]    [0015]FIG. 9 is a rear perspective view of the canopy of FIG. 1;  
         [0016]    [0016]FIG. 10 is a side elevational view of the canopy of FIG. 1;  
         [0017]    [0017]FIG. 11 is a front elevational view of the canopy of FIG. 1;  
         [0018]    [0018]FIG. 12 is a top perspective view of a front, side portion of the canopy of FIG. 1;  
         [0019]    [0019]FIG. 13 is a bottom perspective view of a front, side portion of the canopy of FIG. 1;  
         [0020]    [0020]FIG. 14 is a cross-sectional view along line  14 - 14  in FIG. 12;  
         [0021]    [0021]FIG. 15 is a cross-sectional view along line  15 - 15  in FIG. 12;  
         [0022]    [0022]FIG. 16 is a side perspective view of a front, side portion of the canopy of FIG. 1 illustrating water flow from a preferred drain hole of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    The preferred embodiments will be described with reference to the drawing figures with like numbers representing like elements throughout.  
         [0024]    Referring to FIG. 1, there is shown a schematic, perspective front view of a golf car incorporating features of the present invention. The golf car  1  generally comprises a chassis body  3 , wheels  5 , a motor  7  for driving wheels  5 , a passenger sitting area  9 , a golf bag storage area  11 , a utility storage area (not shown), and a sunroof canopy assembly  15 . The canopy assembly  15  generally comprises a generally rectangular roof canopy  20 , a front support frame  22 , and a pair of rear support frames  24 ,  25 .  
         [0025]    As shown in FIG. 2, front support frame  22  is comprised of a generally U-shaped tubular member having a bottom section  26  and two upwardly extending legs  28  with each leg terminating in a rearwardly extending portion  30 . Each portion  30  extends into a slotted front side member  32  formed integrally on the underside of the canopy  20  adjacent the respective side edge. As illustrated in circled portion  34  of FIG. 2, portion  30  is bolted to slotted member  32 . The bottom section  26  of the front support frame is fastened to the chassis  3 .  
         [0026]    Rear support frames  24 ,  25  each include a bottom portion  36  fastened to chassis  3  at bag storage area  11  (as illustrated in circled portion  37  of FIG. 2) and an upwardly extending portion  38  which terminates in a forwardly extending portion  40 . Each portion  40  extends into a slotted rear side member  42  formed integrally on the underside of the canopy  20  adjacent to the respective side edge. As illustrated in circled portion  44  of FIG. 2, portion  40  is bolted to slotted member  42 .  
         [0027]    Referring to FIG. 3, canopy  20  is formed into a single sheet of thermoplastic material, preferably polypropylene, using gas assisted molding procedures. Canopy  20  has a top surface  50 , a bottom surface  52  and edges that form a canopy perimeter, including a front canopy perimeter portion  54 , a rear canopy perimeter portion  56 , and substantially parallel first and second side canopy perimeter portions  58 ,  60  extending between the front and rear perimeter portions  54 ,  56 . As can be seen in FIGS.  5 - 10 , the edges defining the perimeter are rounded, thereby reducing the potential for injury, if for example, a passenger were to strike their head against such. The edges preferably further include a drip edge bead  153  depending therefrom, see FIGS.  13 - 15 , the function of which will be described hereinafter.  
         [0028]    A first handgrip  62  is formed integrally on first canopy side perimeter portion  58 . A second handgrip  64  is formed integrally on second canopy side perimeter portion  60 . Handgrips  62 ,  64  are located at a rearward position of canopy  20  approximately an equal distance from rear canopy perimeter portion  56 . Each handgrip  62 ,  64  is defined by an aperture  65  through the canopy  20  which further defines a gripping member  70 . The gripping members  70  preferably extend inward moving from front to back. As such, the transverse width  66  of the front portion of canopy  20  is wider than the transverse width  68  of the portion of canopy  20  extending between the gripping members  70  and each gripping member is completely within the extent of the front canopy portion width  66 . This allows the front canopy portion to shield hands holding the gripping members  70  of handgrips  62 ,  64  as car  1  moves forward.  
         [0029]    Referring to FIGS. 4 and 5, the canopy  20  includes a plurality of hollow channel stiffeners  72 ,  74 ,  90 . First hollow stiffener channel  72 , formed integrally in the sheet of canopy  20  at the sheet edges, extends along the front canopy perimeter  54 , along side canopy perimeters  58 ,  60 , through gripping member  70  and terminates adjacent rear canopy perimeter portion  56 . Channel  72  forms a gently curved perimeter offering protection against injury to passengers. Channel  72  is hollow as a result of the gas assisted injection mold process, and provides stiffness to the sheet of the canopy  20 . Hollow channel  72  is further shown in FIGS.  6 - 9 .  
         [0030]    Likewise providing stiffness is second, hollow channel  74  formed integrally into the sheet of canopy  20  in-board of first stiffener channel  72 . Second stiffener channel  74  has a front channel portion  76  and first and second side channel portions  78 ,  80  extending parallel to front and side canopy perimeter portions  54 ,  58  and  60 , respectively. Channel portions  78 ,  80  each terminate in a bifurcated, rearward hollow channel section that encloses a respective slotted rear member  42  that is formed integrally into canopy  20 . Integral slotted front members  32  are also shown. Thus, it can be seen that second stiffener  74  forms a generally U-shaped stiffener that parallels front canopy perimeter  54  and curves rearwardly to extend parallel to side canopy perimeter portions  58 ,  60 , respectively. Hollow channel  74  is further shown in FIGS.  6 - 9 .  
         [0031]    Providing added stiffness is a plurality of third, hollow stiffeners  90  formed integrally into the sheet of canopy  20 , in-board of second, hollow stiffeners  74 . Stiffeners  90  are separate, longitudinal hollow channels extending parallel to side canopy perimeter portions  58 ,  60 . We prefer four stiffeners  90 , but fewer or more will work. Stiffeners  90  intersect front channel portion  76  and terminate adjacent rear canopy perimeter portion  56 . Hollow channels  90  are further shown in FIGS. 6, 8 and  9 .  
         [0032]    We prefer to provide canopy surface  112  with a plurality of secondary depressions  114  directly above hollow channels  90  to cosmetically mask any distortions or wrinkling associated with channels  90 , although a smooth or pebbled surface will work.  
         [0033]    We have successfully provided a canopy in accordance with this invention with a wall thickness in the range of 0.100 to 0.125 inches, from the following thermoplastic material: 20% calcium carbonate filled, high impact polypropylene copolymer.  
         [0034]    Referring to FIG. 3, the location and orientation of the preferred drain gutters  100 ,  106  on canopy  20  will be described. First drain gutter depression  100  is formed into the sheet of canopy  20  and extends adjacent to front canopy perimeter  54  and curves rearwardly to extend along canopy perimeters  58 ,  60 , forming a U-shaped gutter terminating at handgrips  62 ,  64 . A drain hole  102  is located at each front comer  104  of gutter  100 . The second drain gutter depression  106  is formed into the sheet of canopy  20  and extends substantially parallel to the entire perimeter of canopy  20 , forming a generally rectangular shaped gutter. The side walls of gutter  106  part to form a drain aperture  108  at each rear comer  110 . As shown in FIGS. 5 and 9- 11 , first drain gutter  100  slopes gently forwardly, rear to front, to direct water to drain holes  102 . Second drain gutter  106  slopes gently rearwardly, front to rear, to direct water to rear comer apertures  108 . As shown in FIG. 11, central canopy surface  112  slopes gently transversely, side to side, to direct water to gutter  106 .  
         [0035]    Water flow from drain holes in general can be characterized as “wickingdominated” or “stream-dominated” flow. With wicking-dominated flow, water flowing through the drain hole briefly adheres (“wicks”) to the canopy surface adjacent the drain hole. The adhesion of the water particles causes the water flow to be diverted along the underside of the canopy prior to the water particles shearing off and falling downwardly under the influence of gravity. Wicking-dominated flow is preferred, provided it is controlled, i.e., the flow is diverted away from the vehicle chassis. In many prior art devices, the wick flow is random at best, and in many instances, the flow is actually diverted toward the vehicle chassis.  
         [0036]    With stream-dominated flow, water flow through the holes is more substantial, in the manner of fluid exiting a pipe, and the water particles do not adhere to the canopy, but instead fall downwardly immediately upon exiting the hole. Such flow may arise during heavy rains when the gutter significantly fills with water. This type of flow is generally not desired since it is difficult to control and the water often falls directly into the vehicle. Another problem with heavy rain is that, even with stream flow, the drain holes are incapable of draining the water from the gutter fast enough. When the gutter overflows, the water tends to wick around the edge of the canopy to the underside from where it typically falls into the vehicle.  
         [0037]    Referring to FIGS.  12 - 16 , the preferred drain holes  102  of the present invention are shown. Each drain hole  102  is generally triangular-shaped with a receiving edge  152  extending between intersecting legs  150 ,  151 . The receiving edge  152  is preferably positioned adjacent the gutter&#39;s lowest elevation, i.e., the elevation to which the water naturally flows. The hole  102  is of a large cross-section relative to the generally round holes of the prior art. The relatively large cross-sectional area allows for a greater flow rate of water through the hole  102 , thereby reducing the likelihood water will pool in the gutter  100  and overflow therefrom. In the event any water does overflow from the gutter  100  or any other portion of the canopy  20 , the drip edge bead  153  prevents the water from wicking around the edge to the underside of the canopy  20 . As shown in FIG. 15, the drip edge bead  153  provides a rounded edge with opposed sides  157   a,b  substantially parallel to the underside of the canopy  20  and a tip of minimized surface area  155  extending therebetween. In order to wick to the underside of the canopy  20 , the water would have to maintain adherence over the minimized surface area  155  and then travel up the inside wall  157   b , against gravity, toward the canopy underside. As such, the water has a much greater tendency to sheer at the minimized surface area portion  155  and fall to earth under the influence of gravity, thereby reducing the occurrence of wicking to the underside of the canopy  20 . The drip edge bead  153  is preferably provided about the entire canopy perimeter such that water flow down any edge portion will be deterred from wicking onto the underside of the canopy  20 .  
         [0038]    The receiving edge  152  of the drain hole  102  has a relatively long receiving ledge  154  formed in the upper surface  50  of the canopy  20  and a relatively long exit ledge  156  formed in the lower surface  52 . By relatively long, it is meant a maximum length L equal to or greater than the height H of the hole. The receiving ledge  154  directs water into the hole  102  while the exit ledge  156  directs the water exiting the hole  102  outward, toward the perimeter of the canopy  20 . The receiving and exit ledges  154 ,  156  are joined by a smooth, arcuate transition  158 . The relatively large size of the ledges  154 ,  156  tend to spread the water out, thereby allowing greater adhesive contact of the water to the surfaces. The smooth transition  158  allows the adhered water to flow between the ledges  154 ,  156 , and thereby change direction (inward to outward), without interrupting the adhesion.  
         [0039]    The adhered water exiting the hole  102  is directed to a directing ledge  160  protruding from the underside of the canopy  20  and extending between the exit ledge  156  and the edge of the canopy  20 . The directing ledge  160  generally maintains the water within its side boundaries, as opposed to a simple flat canopy surface which may allow random spreading of the water. The directing ledge  160  has a slight downward slope as it runs from the drain hole  102  to the edge of the canopy  20  where it intersects the drip edge bead  153 . In the preferred embodiment, the directing ledge  160  is flush with the drip edge bead tip  155 . The downward slope allows gravity to aid in speeding up the water W flow along the directing ledge  160  such that the water droplets are effectively propelled from the edge of the canopy  20  before falling to earth, as illustrated in FIG. 16. The drip edge bead  153  again helps to ensure sheering of the water as it reaches the edge of the canopy  20 .  
         [0040]    While the preferred drain holes  102  and the drip edge bead  153  have been described in conjunction with the preferred canopy  20  and gutter system of the present invention, it is understood that they may also be used in conjunction with other canopies and gutter systems.