Abstract:
The preferred embodiment of a sunroof includes a sunroof panel, a track, an acutating mechanism, and a panel securing member operable to assist in securing a rear section of the panel to the track when the panel is in a closed position. In another aspect of the present invention, a lock assembly includes a spring biased finger and a panel securing member which are movable relative to a track to secure a rear section of a sunroof panel depending on the positional relationship of the finger relative to a camming member.

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     The present invention generally pertains to sunroofs for use in automotive vehicles and more particularly to spoiler sunroof locking, actuating and sealing systems. 
     Two basic types of motorized sunroofs are commonly used in automotive vehicles. A first type is a drop down opening version where a generally flat glass or metal sunroof panel is movable from a closed position to a tilted venting position and then to a fully open position disposed beneath a stationary roof of the vehicle. The second type is known as a spoiler sunroof. In most spoiler sunroofs, the sunroof panel is movable from a closed position to a venting position and then to a fully open position with a rear section of the panel being disposed above the fixed roof. Spoiler sunroofs are often used when the stationary roof behind the sunroof is relatively small or where it is desired to maximize occupant head room in the passenger compartment. 
     Examples of various conventional sunroof actuating mechanisms are disclosed in the following U.S. Pat. Nos.: 5,765,908 entitled “Adjustment Apparatus for a Sunroof” which issued to Kelm on Jun. 16, 1998; 5,746,475 entitled “Drive Mechanism for an Automotive Vehicle Sunroof Assembly” which issued to Caye et al. on May 5,1998; 5,580,123 entitled “Sun-Roof Device” which issued to Ochiai on Dec. 3, 1996; 5,326,149 entitled “Blocking Device for Sliding-Lifting Roofs for Automobile” which issued to Schlapp on Jul. 5, 1994; 5,069,501 entitled “Spoiler Sunroof Control Mechanism” which issued to Baldwin et al. on Dec. 3, 1991; and 4,877,285 entitled “Open Roof Construction for a Vehicle” which issued to Huyer on Oct. 31, 1989. 
     In accordance with the present invention, a preferred embodiment of a sunroof includes a sunroof panel, a track, an actuating mechanism movably coupling the panel to the track, and a panel securing member operable to assist in securing a rear section of the panel to the track when the panel is in a closed position. In another aspect of the present invention, a lock assembly includes a spring biased finger and a panel securing member which are movable relative to a track to secure a rear section of a sunroof panel depending on the positional relationship of the finger relative to a camming member. A further aspect of the present invention provides an abutment structure projecting from a device movably associated with a sunroof panel or actuating mechanism for abutting against a stationary track to deter inadvertent collapsing of the panel when in a raised position. Still another aspect of the present invention employs a lever having a lifting pivot coupled to a sunroof panel assembly, a fulcrum movably coupled to a stationary track, and a camming pin interfacing with a movable camming surface. In yet another aspect of the present invention, a bulbous seal has a pair of spaced apart and generally parallel legs mounted to a sunroof housing. 
     The sunroof of the present invention is advantageous over traditional constructions in that the lock assembly of the present invention couples movement of a front camming mechanism to engagement and disengagement of the panel securing member which operably secures the rear section of the sunroof panel in its closed position. The mechanical movements of the present invention lock assembly provide very reliable, smooth and low effort operational forces due, in part, to transverse spring biasing of a finger relative to the remainder of the lock assembly while also employing linear fore and aft spring biasing of the lock assembly relative to the stationary track; geometrically complicated cams are unnecessary to achieve the desired lock assembly finger-to-actuating mechanism interface. Furthermore, the preferred shape and materials of the preferred embodiment finger of the present invention provide inherent lubricity and low effort disengagement between lead in angles of the finger and the actuating mechanism. 
     The specific lever and camming arrangement of the present invention actuating mechanism enhance stability and strength of the spoiler sunroof, while minimizing packaging space and cost, especially as compared to many conventional constructions. The specific geometric positioning of the fulcrum, lift pivot and camming pin of the present invention lever achieve a well balanced, powerful and compact mechanism to tilt the sunroof panel. This is further enhanced by the general prevention of vertical movement of the fulcrum relative to the track. Additionally, the abutment structure serves as a failsafe way of deterring undesired collapsing of the venting or open sunroof panel. This supplemental device is especially useful in preventing contact of the sunroof panel against the stationary roof when the vehicle is traveling at high speeds or when a person pushes against the panel when open. Moreover, the present invention seal is advantageous by promoting generally vertical bulb compression when the sunroof panel is moved from an open or venting position, to a closed position. This vertical sealing movement serves to minimize the necessary closing forces of the sunroof panel relative to the track and housing, which also reduces required power of the motor. Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a fragmentary and partially exploded perspective view showing the preferred embodiment of a spoiler sunroof of the present invention; 
     FIG. 2 is an exploded perspective view showing the preferred embodiment spoiler sunroof; 
     FIG. 3 is a fragmentary and exploded side elevational view showing the preferred embodiment spoiler sunroof; 
     FIG. 4 is a side elevational view showing the preferred embodiment spoiler sunroof disposed in a fully closed position; 
     FIG. 5 is a top elevational view showing the preferred embodiment spoiler sunroof in the fully closed position; 
     FIG. 6 is a side elevational view showing the preferred embodiment spoiler sunroof disposed in a closed but unlocked position; 
     FIG. 7 is a top elevational view showing the preferred embodiment spoiler sunroof disposed in the closed but unlocked position; 
     FIG. 8 is a side elevational view showing the preferred embodiment spoiler sunroof disposed in a venting and partially open position; 
     FIG. 9 is a top elevational view showing a lock assembly of the preferred embodiment spoiler sunroof; 
     FIG. 10 is a side elevational view showing the lock assembly of the preferred embodiment spoiler sunroof; 
     FIG. 11 is a diagrammatic top view showing a finger of the lock assembly and a cam block employed in the preferred embodiment spoiler sunroof, disposed in the fully closed and locked position; 
     FIG. 12 is a diagrammatic top view showing the finger and cam block employed in the preferred embodiment spoiler sunroof, disposed in an intermediate locked position; 
     FIG. 13 is a diagrammatic top view showing the finger and cam block employed in the preferred embodiment spoiler sunroof, disposed in an intermediate unlocked and venting position; and 
     FIG. 14 is a cross sectional view, taken along line  11 — 11  of FIG. 1, showing a seal and housing of the preferred embodiment spoiler sunroof. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1-3, the preferred embodiment of a spoiler sunroof  21  of the present invention includes a sunroof panel assembly  23 , a metal housing  25 , a panel lifting and actuating mechanism  27 , a stationary track  29 , a lock assembly  31 , and a metal reinforcing pan  33 . Housing  25  and reinforcing pan  33  serve to secure a pair of tracks  29  and the associated mechanisms to a stationary fixed roof  35  (see FIG. 14) of an automotive vehicle. 
     Sunroof panel assembly  23  includes a generally horizontal (when losed) and planar glass panel  41 , a bracket  43 , a catch  45  and a metal reinforcement  47 . Bracket  43  and catch  45  are glued onto a bottom surface of panel  41 . Bracket  43  has a bifurcated front end  48  and a threaded fastener for disengagably attaching to reinforcement  47 . Bifurcated end  48  captures an edge  49  of an opening in reinforcement  47 . Once assembled, reinforcement  47 , bracket  43  and panel  41  always move in unison. 
     Actuating mechanism  27  includes a cam block  51  and a lift lever  53 . A flocked and wire wound cable  55  pushes and pulls cam block  51  within a groove  58  of track  29 . SUFLEX brand cable which can be purchased from Suhner Manufacturing, Inc. of Rome, Ga., has been found suitable. Cable  55  is operably driven by energization of a fractional horsepower, direct current electric motor (not shown) mounted to a front edge of reinforcing pan  43 . Cam block  51  has a slotted, S-shape camming surface  57 . Camming surface  57  increases in height adjacent a rear edge of cam block  51 . A metal, circular-cylindrical block pin  59  laterally projects in a crosscar manner from a lateral face of cam block  51 . Block pin  59  movably rides within a slotted camming surface  61  projecting in a longitudinally fore and aft direction of a downturned flange of reinforcement  47 . A bushing  63  is provided as part of block pin  59 . Feet  65  of cam block  51  ride within groove  58  and the main body of cam block  51  vertically projects through an elongated upper opening of track  29 . A depressed pocket or aperture  67  is disposed in a lateral face of cam block  51  opposite slotted camming surface  57 . 
     Lifting lever  53  has a lifting pivot segment  81  which is fastened to a rear segment of reinforcement  47  by way of a pair of bushings  83  and a pivot pin  85 . Pivot pin  85  is secured in holes of reinforcement  47  by use of a lock ring  87 . Lever  53  further has a central fulcrum pin  89  pivotably journalled between a pair of bushing shoes  91 . Shoes  91  are operable to move in a fore and aft direction inside groove  58  of track  29 . However, the fulcrum pin is essentially prevented from vertically moving relative to track  29 . Furthermore, a camming extension pin  93  of lever  53  rides along camming surface  57  of cam block  51 . Thus, fore and aft movement of cam block  51  causes vertical lifting or lowering of camming pin  93  along camming surface  57 . This further causes rotation of lever  53  about fulcrum pin  89  which, in turn, serves to vertically lift and tilt reinforcement  47  and panel  41 . The relationship of lifting pivot segment  81 , camming pin  93  and fulcrum pin  89  form a triangular shape thereby compactly balancing and maximizing mechanical forces required to lift and lower sunroof panel assembly  23 . Cam block  51  and lever  53  are both preferably injection molded from glass-filled Nylon 6/6. Track  29  and reinforcement  47  are preferably made from aluminum. 
     An L-shaped camming slot  101  is stationarily mounted in track  29 . A main pivot pin  103  laterally projecting from downturned flange of reinforcement  47  for movably riding within camming slot  101 . This allows vertical initial and final movement of reinforcement  47  and panel  41  relative to track  29  and a weatherstrip seal  105 . A cam stop  107  is also mounted to track  29 . 
     As can best be observed in FIGS. 2,  9  and  10 , lock assembly  31  has a circular-cylindrical shaft  121 , an enlarged two-part head  123  and a panel assembly securing hook  125 . A finger  127  is mounted to head  123  by way of a music wire, torsion spring  129 . Torsion spring  129  has a coil and a first end disposed inside of head  123 . An opposite L-shaped end is injection molded within finger  127 . An outer periphery (as viewed from the top, like FIG. 9) of finger  127  has a predominantly curved shape. A nib  131  upwardly extends from a trailing end of lock assembly  31  for engagement by a hook of a music wire extension spring  133 . A spring stop  135  has an elongated circular-cylindrical shank  137 , a keyhole shaped body  139  and an enlarged head  141 . Another hook of extension spring  133  engages a nib  143  upwardly extending from shank  137 . Shaft  121  of lock assembly  31 , extension spring  133 , shank  137 , and body  139  are all disposed in another channel or groove  151  of track  29 . Spring stop  135  is inserted into an end of groove  151  but head  141  prevents complete insertion. Lock assembly  31  is allowed to move in a fore and aft manner within groove  151  and is biased toward spring stop  135  by extension spring  133 . Finger  127  and hook  125  project above track  29 . Lock assembly  31  and springs top  135  are preferably injection molded from glass-filled Nylon 6/6. 
     The operation of spoiler sunroof  21  of the present invention will now be explained in greater detail. FIGS. 4,  5  and  11  illustrate the spoiler sunroof and all of its mechanisms in a fully closed position covering a sunroof opening. The left side of these figures would be forward in the automotive vehicle. In this fully closed orientation, main pivot  103  of reinforcement  47  is in the lowest and forwardmost possible position relative to camming slot  101  of track  29 . Furthermore, block pin  59  is disposed in a forwardmost and uppermost possible position relative to camming surface  61  of reinforcement  47 . It is noteworthy that these slotted camming surfaces  61  and  101  allow for additional adjusted movement of reinforcement  47  and the sunroof panel relative to seal  105  (see FIG. 14) if the seal does not continue to fully flex to its original position after many years of use. Thus, complete panel-to-seal compression is assured. Furthermore, cam block  51  is located in its forwardmost advanced position when the spoiler sunroof is fully closed. This causes camming pin  93  to be in its uppermost raised orientation relative to camming surface  57 . Lifting pivot  81  is thereby rotated about fulcrum pin  89  to its lowest possible position. 
     In this fully closed position, finger  127  of the lock assembly will engage depressed aperture  67  of cam block  51 . Extension spring  133  is extended in this position and unable to pull head  123  or finger  127  since finger  127  is laterally wedged between an inwardly extending tab  201  of housing  25  and cam block  51 . Hook  125  engages a lateral arm  203  (see FIG. 1) of catch  45  (also see FIG.  1 ), when the lock assembly is in its forwardmost position. Therefore, hook  125  serves to secure a rear section of the sunroof panel in its desired closed position, despite pressure changes within the vehicle passenger compartment due to passenger door closing, or when the panel would otherwise move due to rough road driving. 
     Hook  125  is disengaged from catch  45  (see FIG. 1) when cam block  51  is moved from the fully advanced position shown in FIGS. 4,  5  and  11  to the unlocked position shown in FIGS. 6,  7  and  13 . FIG. 12 shows an intermediate position wherein finger  127  of the lock assembly is rearwardly retracted in concert with cam block  51 . In the unlocked state of FIGS. 6,  7  and  13 , reinforcement  47  and lever  53  remain unchanged relative to track  29 . However, cam block  51  has been slightly moved in a linearly rearward direction. This causes finger  127  to flex out of depressed aperture  67  in a crosscar direction once clear of tab  201 . Rearward movement of finger  127  causes a simultaneous rearward disengagement of hook  125  from catch  45  (see FIG.  1 ). This allows subsequent tilting movement of the sunroof panel. 
     Further energization of the electric motor causes rearward retraction of cam block  51 . First, main pivot  103  of reinforcement  47  is upwardly cammed along camming slot  101 . This causes vertical decompression of seal  105  (see FIG.  14 ). At the same time, camming pin  93  is caused to begin riding down camming surface  57  of cam block  51 , thereby upwardly tilting the rear section of reinforcement  47  and the sunroof panel. In the fully tilted venting position, as shown in FIG. 8, block pin  59  abuts against a rearmost edge of camming surface  61  of reinforcement  47 . Also, camming pin  93  of lever  53  abuts against a forwardmost edge of camming surface  57  of cam block  51 . Second, further rearward movement of cam block  51  causes the sunroof assembly to linearly move in a fore and aft manner in the spoiler-like tilted orientation until it is fully open. In the fully open position (not shown), the rear section of reinforcement  47  and the sunroof panel will be upwardly tilted and overlap the rear section of housing  25  and the adjacent stationary roof. The preceding motions are reversed to close the sunroof. Various hall effect sensors and microprocessor control units may be employed in the electrical circuit associated with energization of the electric motor, in order to define preset venting or other positions. A sliding sunshade unit can also be used to selectively cover the lower surface of the sunroof panel. 
     FIG. 14 shows a typical section of the preferred embodiment seal  105 . Seal  105  has a hollow bulbous section  221  with a compressible internal air pocket  223 . A finger  225  with a free-standing edge  227  outwardly and upwardly extends from bulbous section  221 . A pair of hollow legs  229  and  231  downwardly project from bulbous section  221 , in a spaced apart yet parallel manner. An air pocket  233  is disposed within each leg  229  and  231 . A series of projections  235  extend around the complete periphery of legs  229  and  231 . Once installed, legs  229  and  231  are separated by an upstanding wall  251  of housing  25 . A primer and adhesive are disposed in housing pockets  255  and  257  which receive legs  229  and  231 , respectively. Seal  105  is extruded from a silicone rubber having an approximately  70  durometer. Two air access holes (not shown) are disposed through an interior upper edge of bulbous section  221  to allow for seal compression. Finger  225 , the adjacent portion of bulbous section  221  and the adjacent vertical side wall of housing  25  optimally serve as a water carrying channel. Furthermore, the vertical compression of bulbous section  221  optimizes panel-to-housing sealing far better than the traditional horizontally extending weatherstrip projecting from a horizontal housing flange. 
     While the preferred embodiment of the spoiler sunroof has been disclosed, it will be appreciated that various other embodiments may fall within the scope of the present invention. For example, various aspects of the disclosed invention, such as the lock assembly and seal, may be employed for non-spoiler type sunroofs. Furthermore, other camming shapes and motions can be employed. Additionally, a metal sunroof panel can be readily substituted for the preferred glass panel. While various materials, shapes and sizes have been disclosed, other materials, shapes and sizes may be employed. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention.