Abstract:
A roof rail assembly for a vehicle that includes a body side outer and an interior trim piece connected to the body side outer. The body side outer and the interior trim piece define a cavity. A roof rail is positioned within the cavity, and a side curtain air bag is positioned below the roof rail. The interior trim piece is assembled about a lower surface of the roof rail in a spaced relationship relative to the curtain air bag to increase visibility around the roof rail assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 14/045,743 filed Oct. 3, 2013, now U.S. Pat. No. 8,967,662 issued Mar. 3, 2015, the disclosure of which is hereby incorporated in its entirety by reference herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to vehicle roof support structures with vehicle roof rail assemblies and side curtain air bags. 
     BACKGROUND 
     A vehicle roof assembly may consist of a roof panel supported by roof support pillars and a roof rail. The roof support pillars are designated as an A-pillar, B-pillar, C-pillar, and so on. The roof rail extends along a longitudinal axis of the vehicle from the vehicle&#39;s A-pillar up to the vehicle&#39;s last pillar, such as a C-pillar. On the vehicle exterior, the roof rail is covered by an outer body panel attached to the roof panel. Inside the vehicle, the roof rail is covered by an inner trim panel. Electrical wire bundles and folded side curtain air bags may be positioned in between the roof rail and the inner trim panel. The inner trim panel attached to the roof rail that enclose the electrical wire bundle and folded side curtain air bags is spaced from the outer body panel and reduces occupant vision and interior space. The width of the roof rail and the inner trim panel also reduces the space for ingress and egress of occupants in low profile vehicles, such as coupes and sports cars. 
     The above problems and other problems are addressed by this disclosure as summarized below. 
     SUMMARY 
     An aspect of the present disclosure relates to a roof support structure for a vehicle. The roof support structure includes a roof panel and a pair of A-pillars supporting a front end of the roof panel. Each of the A-pillars is disposed between the windshield and a side door window. The roof support structure further includes a pair of roof rails extending in a longitudinal direction on right and left sides of the roof panel. A side curtain air bag is assembled to each one of the A-pillars and one of the roof rails. The roof rail from A-pillar to C-pillar defines a concave recess extending along the length of the roof rail. The concave recess opens toward a passenger compartment of the vehicle and has a smooth curved surface. The side curtain air bags are folded and assembled into the concave recess with at least half of the outer surface of the curtain air bag contacting the smooth curved surface of the concave recess. 
     Other aspects of the vehicle roof support structure include a guide surface provided on at least one side of the concave recess. The guide surface is preferably a planar member that extends from the concave recess toward the passenger compartment of the vehicle. The guide surface facilitates smooth deployment of the curtain air bag. The smooth curved surface of the concave recess may be an oval surface and the curtain air bag may be folded into an oval cross-sectional shape. 
     Another aspect of the present disclosure relates to a vehicle roof rail assembly that supports one side of a roof of a vehicle. The vehicle roof rail assembly includes an elongated tubular roof rail having an outer wall that is convex, an inner wall that defines a concave area, and a rib extending downwardly from and disposed between the outer wall and the inner wall. The vehicle roof rail assembly further includes an outer body panel attached to the outer wall, an active restraint air bag disposed at least partially within the concave area of the inner wall, and an inner trim panel spanning the inner wall and enclosing the folded curtain air bag. 
     In other aspects of the vehicle roof rail assembly, the outer body panel defines an inner surface that defines a cavity and wherein the outer wall of the roof rail is received within the cavity defined by the inner surface of the outer body panel. At least half of the curtain air bag may be received within the concave area of the inner wall. The inner trim panel may be attached to the rib and extends in an inboard direction to enclose the curtain air bag. The vehicle roof rail assembly may further include a guide surface provided on at least one side of the concave recess. The guide surface is a planar member that extends from the concave area of the inner wall toward a passenger compartment of the vehicle. A door seal may be attached to an outwardly facing surface of the rib adjacent to the juncture of the outer wall and the inner trim panel. The lateral width of the air bag, the rib and the door seal may be less than the width of the roof rail in the transverse vehicle direction. The rib may define a seal recess on an outer seal receiving wall that is separated from the concave area of the inner wall. A door seal is attached to the outer seal receiving wall, and the side curtain air bag and the door seal are disposed above a lower end of the rib. 
     Another aspect of the present disclosure relates to a vehicle roof rail assembly that includes a body side outer and an interior trim piece connected to the body side outer. The body side outer and inner trim panel define a cavity. A roof rail positioned is within the cavity. A side curtain air bag is positioned below the roof rail. The inner trim panel is assembled about a lower surface of the roof rail in a spaced relationship relative to the side curtain air bag to increase visibility around the A-pillar/roof rail assembly for an occupant in the vehicle. 
     In other aspects of the vehicle roof rail assembly, the roof rail is in a form of an asymmetrical p-shaped roof rail. The roof rail includes an elongate portion and a loop portion attached to the elongate portion. The loop portion is tucked into the cavity to reduce the distance between the inner trim panel and the body side outer. The body side outer has an inner surface, and the loop portion follows the contours of the inner surface of the body side outer. The elongate portion may be bent to form a concave inner wall. The curtain air bag is positioned at least partially within the concave inner wall of the roof rail. The curtain air bag may have a circular or an oval cross-section. 
     The above aspects and other aspects of this disclosure are described below in greater detail with reference to the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a fragmentary side elevation view of a vehicle having an A-pillar and a roof rail structure of the present disclosure. 
         FIG. 2  is a cross-section view taken along line  2 - 2  in  FIG. 1  showing a roof rail and a side curtain air bag of a roof rail assembly embodiment. 
         FIG. 3  is a cross-section view similar to the view in  FIG. 2  showing an alternative embodiment of a roof rail and a side curtain air bag. 
         FIG. 4  is a cross-section view similar to the view in  FIG. 2  showing an alternative embodiment of a roof rail and a side curtain air bag. 
         FIG. 5  is a cross-section view similar to the view in  FIG. 2  showing an alternative embodiment of a roof rail and a side curtain air bag. 
     
    
    
     DETAILED DESCRIPTION 
     The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts. 
     Referring to  FIG. 1 , a vehicle  20  incorporating the roof rail assembly of the present disclosure includes a roof panel  22  supported by a pair of A-pillars  24 , B-pillars  26 , and C-pillars  28 . Each of the pair of A-pillars  24  is disposed between a windshield and a side door window. The type of vehicle  20  that is shown is a sedan but the roof rail assembly may be incorporated with any type of vehicle, including those with more or less supporting pillars. The roof panel  22  may be supported by roof bows and a pair of roof rails extending in a longitudinal direction on the right and left sides of the roof panel of the vehicle  20 . Each of the roof rails is covered by an outer body panel  30 . The roof panel  22  and the outer body panel  30  may be the same panel, or they may be one panel. Certain portions of the outer body panel  30  may form a part of any of the pillars—A, B, or C. The outer body panel  30  is connected to door frames  32  and  34 . 
     Referring to  FIG. 2 , the roof panel  22 , the outer body panel  30 , and the door frame  34  form the exterior periphery of a top portion of the vehicle  20 . The roof panel  22  and the outer body panel  30  are connected at a roof ditch  23 . A roof rail assembly section  25  includes the outer body panel  30 , a inner trim panel  44 , a roof rail  50 , and a side curtain air bag  48 . The outer body panel  30  has an inner surface  56  that defines a concave recess extending longitudinally on the vehicle  20 , including the applicable pillars of the vehicle  20 . The concave recess opens toward a passenger compartment of the vehicle  20  and has a smooth curved surface. The outer body panel  30  includes a first rib  36  adjacent to the roof ditch  23  that downwardly extends in an inboard direction followed by a flange  36   a . The flange  36   a  bends and forms a first planar guide surface  37 . The outer body panel  30  further includes a second rib  39  at an end opposite to where the first rib  36  extends. The second rib  39  includes a downwardly extending portion  41 . The downwardly extending portion  41  bends and forms a planar surface  43 . 
     A first door seal  38  is attached to the downwardly extending portion  41  of the second rib  39 . A second door seal  40  is attached to the outwardly facing planar surface  43  of the second rib  39  that is adjacent to a juncture of the outer body panel and the inner trim panel. Door seals  38  and  40  are positioned in between the door frame  32  and the second rib  39  to prevent elements, such as water and noise, from entering the vehicle  20 . 
     An inner trim panel  44  is attached to the planar surface  43  and extends in an inboard direction. The inner trim panel  44  and the outer body panel  30  define a cavity  46  where a side curtain air bag  48 , electrical wires, and a roof rail  50  are positioned. The cavity  46  includes a first pocket  47  defined by an inner surface  54  of the first rib  36 , an inner surface  56  of the outer body panel  30 , and an inner surface  58  of the downwardly extending portion  41  of the second rib  39 . The cavity  46  further includes a second pocket  49  defined by an inner portion  62  of the planar surface  43  and the inner surface  64  of the inner trim panel  44 . 
     The roof rail  50  is preferably an elongated tubular roof rail and includes a first convex outer wall  52  connected to a second convex outer wall  53 . The second convex outer wall  53  is connected to a concave inner wall  66 , and the concave inner wall  66  is connected to a third convex outer wall  55 . The first convex outer wall  52  is disposed within the first pocket  47 , and the second convex outer wall  53  is disposed within the second pocket  49 . The third convex outer wall  55  is connected to the first convex outer wall  52  at an end that is opposite to the second convex outer wall  53 . The third convex outer wall  55  is positioned below the inner surface  54 . The concave inner wall  66  is connected to the third convex outer wall  55  on one end and the second convex outer wall  53  on the other end. The concave inner wall  66  opposes the first pocket  47  and faces the inner trim panel  44 . The concave inner wall  66  opens toward the passenger compartment of the vehicle. The concave inner wall  66  preferably includes a smooth curved surface and is an oval surface. A second guide surface  63  may be provided on at least one side of the concave inner wall  66 . The second guide surface  63  is a planar member that extends from the concave inner wall  66  toward a passenger compartment of the vehicle. The second guide surface  63  enables the side curtain air bag to deploy smoothly. 
     The side curtain air bag  48  is preferably tucked in the concave inner wall  66 . At least half of the outer surface of the side curtain air bag  48  preferably contacts the smooth curved surface of the concave inner wall  66 . At least half of the side curtain air bag  48  is also received within the concave inner wall  66 . The side curtain air bag  48  may be folded into a cylindrical, circular, or an oval cross-sectional shape. The inner trim panel  44  and the outer body panel  30  enclose the side curtain air bag  48 . The curtain air bag  48  extends below the roof rail. The insertion of the first convex outer wall  52  into the first pocket  47 , the insertion of the second convex outer wall  53  into the second pocket  49 , and the position of the side curtain air bag  48  relative to the concave inner wall  66  minimize the size of the roof rail assembly section  25 . The width of the assembly between the outer body panel  30  and the inner trim panel  44  is significantly minimized by placing the side curtain air bag  48  at least partially within the concave inner wall  66 . Consequently, the roof rail assembly section  25  improves the occupant vision and the interior space of the vehicle  20 . The roof rail assembly section  25  also improves the space for ingress and egress of occupants in low profile vehicles, such as coupes and sports cars. 
     Referring to  FIG. 3 , another embodiment of a roof rail assembly is shown and includes a roof rail having an elongate portion  72  and a loop portion  74  attached to the elongate portion  72 . The loop portion  74  is tucked into the first pocket  47  defined by the outer body panel  30  to reduce the distance between the inner trim panel  44  and the outer body panel  30 . The roof rail  70  is an asymmetrical p-shaped roof rail. The asymmetrical p-shaped roof rail includes an elongate portion  72  that is preferably parallel to the planar surface  43 . The elongate portion  72  spans from one end of the inner trim panel  44  to an area adjacent to the end of the first planar guide surface  37 . The asymmetrical p-shaped roof rail also includes a loop portion  74  that is tucked into the first pocket  47  and follows the contours of the inner surface of the outer body panel  30 . The loop portion  74  may include a first side  75  that is parallel to the first planar guide surface  37 , a second side  78  that is parallel to the downwardly extending portion  41 , and a third side  76  connecting the first side  75  and the second side  78 . 
     Referring to  FIG. 4 , yet another embodiment of a roof rail assembly is shown and includes a roof rail  80  that is similar to the asymmetrical p-shaped roof rail  70  of  FIG. 3 , except that its elongate side  82  is bent to form a concave inner wall. The concave inner wall is for accommodating a curtain air bag  48 . The side curtain air bag  48  is received in the concave inner wall. The loop portion  84  of the roof rail  80  is inserted into the first pocket  47 . As a result, the distance between the inner trim panel  44  and the outer body panel  30  can be minimized to improve the occupant vision, and increase the ingress and egress clearance. 
     Referring now to  FIG. 5 , another embodiment of a roof rail assembly is shown and includes a roof rail  90  having a first loop section  92  that is positioned outside the first pocket  47  and a second loop section  94  that is positioned within the first pocket  47 . Roof rail  90  includes a horizontal member  96  that spans from an area adjacent to the inner trim panel  44  to an area within the first pocket  47  adjacent to the second rib  39 . Loop members  98  and  100  preferably connect to the horizontal member  96  and follow the contours of the inner surface of the outer body panel  30 . An elongate member  102  connects loop member  100  to the horizontal member  96  to close the loop. The elongate member  102  is bent substantially in the middle to form a concave inner surface  104  for accommodating a curtain air bag  48 . The elongate member  102  includes a first portion  106  that is substantially parallel to the inner trim panel  44  and a second portion  108  that is substantially parallel to the planar surface  43 . The lateral width of the curtain air bag  48 , the planar surface  43  of the second rib  39 , and the door seal  40  is less than the width of the roof rail  90  in a traverse vehicle direction. 
     While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosed apparatus and method. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure as claimed. The features of various implementing embodiments may be combined to form further embodiments of the disclosed concepts.