Patent Publication Number: US-11648830-B2

Title: Folding soft top with lift assist

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The instant application is a continuation of U.S. patent application Ser. No. 16/567,728, filed Sep. 11, 2019, which is a continuation of U.S. patent application Ser. No. 15/918,587, filed Mar. 12, 2018, issued as U.S. Pat. No. 10,449,843, which is a non-provisional of U.S. Provisional Application No. 62/469,934, filed Mar. 10, 2017, and claims the benefit of U.S. Provisional Application No. 62/469,934, filed Mar. 10, 2017, and which is a continuation-in-part of U.S. patent application Ser. No. 15/861,194, filed Jan. 3, 2018, issued as U.S. Pat. No. 10,583,720, which is a continuation-in-part of U.S. patent application Ser. No. 15/790,836, filed Oct. 23, 2017, issued as U.S. Pat. No. 10,603,994, which is a continuation-in-part of U.S. patent application Ser. No. 15/595,396, filed May 15, 2017, issued as U.S. Pat. No. 10,414,253, which claims the benefit of U.S. Provisional Application No. 62/336,062, filed May 13, 2016, and which also claims the benefit of U.S. Provisional Patent Application No. 62/411,249, filed Oct. 21, 2016, and said U.S. patent application Ser. No. 15/861,194, filed Jan. 3, 2018 also claims the benefit of U.S. Provisional Patent Application No. 62/441,810, filed Jan. 3, 2017. The disclosures of the above applications are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a folding sunroof for a soft top of a vehicle. 
     BACKGROUND OF THE INVENTION 
     Foldable soft tops for SUV vehicles are known in the art. These tops provide a vehicle with an open air experience with the top folded back or provide protection from the elements with the top folded forward. Such tops are typically manually retractable and during retraction the operator has to perform a series of manipulation of the top. Additionally, manual management and stowage of the fabric materials of the top during folding must be accomplished. 
     Thus, in order for a vehicle operator to facilitate opening of the soft top in order to provide the open air vehicle feeling the operator must be outside the vehicle to manipulate the soft top. Therefore, in recent years a soft top “sunroof” has become a well-received option for folding SUV soft tops. This “sunroof” typically folds back from within the vehicle such that the operator can readily provide an open air experience without folding back the entire soft top. An example of such a soft top is a soft top by Bestop, the assignee herein which provides a front “sunroof” portion of the top which folds back for revealing an open air sunroof feeling for the vehicle. 
     While this sunroof option has become a very desirable feature, it does require considerable force at the start of the deployment due to the operator&#39;s angle of attack. The mass of the frame mechanism for folding the top cover fabric and fabric becoming trapped in the frame mechanism linkage are additional concerns. Also, fabric management is occasionally problematic in that the fabric can become entangled or interfere with the frame mechanism of the top. 
     Therefore, there remains a need in the art to provide a sunroof deployment mechanism that provides easier opening and improved fabric management. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, there is provided a soft top assembly which includes lift assist and improved fabric management. The assembly includes a pair of front side arms pivotally attached to rear side rails. The rear side rails are attached to the vehicle roll bar, preferably via rear door rails. A plurality of control bows are operably connected to provide fabric control to the top material during pivoting of the front side rails. Intermediate bows are provided with control linkages which provide management of the fabric thereby keeping the fabric out of the mechanism during opening and closing of the sunroof. A pair of the bow pivot links being pivotally connected to the rear side rail. A rear gas strut and a front gas strut are attached longitudinally to control linkages. One is closed and preloaded when the sunroof is in its closed position and upon opening the sunroof the preloaded strut provides lift assistance at the start of the pivotal opening of the sunroof the other of the struts gets loaded as the top is deployed and buffers the closing of the roof which also loads the strut to provide assistance in the closing direction when it is time to close the sunroof. 
     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 perspective view of the soft top assembly, in a closed position, in accordance with the present invention; 
         FIG.  2    is an enlarged perspective view of circle ‘ 2 ’ of  FIG.  1    depicting an assist mechanism of the soft top assembly in the closed position, in accordance with the present invention; 
         FIG.  3    is a perspective view of the soft top assembly of the present invention with a pivotal portion rotating to an open sunroof position, in accordance with the present invention; 
         FIG.  4    is an enlarged perspective view of circle ‘ 4 ’ of  FIG.  3   , in accordance with the present invention; 
         FIG.  5    is a side elevation view of the soft top assembly depicted in  FIG.  4   , in accordance with the present invention; 
         FIG.  6    is a side elevation view of the soft top assembly of  FIG.  5    depicting further rearward rotation of the pivotal portion, in accordance with the present invention; 
         FIG.  7    is a perspective view of the pivotal portion in the open sunroof position, in accordance with the present invention; 
         FIG.  8    is an enlarged perspective view of circle ‘ 8 ’ of  FIG.  7   , in accordance with the present invention; 
         FIG.  9    is a side elevation view of  FIG.  8   , in accordance with the present invention; 
         FIG.  10    is a perspective view of the pivotal portion during forward rotation from the open sunroof position toward the closed position, in accordance with the present invention; 
         FIG.  11    is a side elevation of  FIG.  10   , in accordance with the present invention; 
         FIG.  12    is a front perspective view of a roller assembly of the soft top assembly slidably connected to a track coupled to a door side rail, in accordance with the present invention; 
         FIG.  13    is perspective view of the soft top assembly depicting a first door rail and a second door rail connected to a vehicle, in accordance with the present invention; and 
         FIG.  14    is perspective view of the soft top assembly illustrating fabric management of a cover, in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     Referring to  FIGS.  1 - 14    generally, in accordance with the present invention, there is provided a soft top assembly generally shown at  10  for a vehicle  12 . The vehicle  12  includes a windshield header  14  with side members  16 ,  18 , e.g., vehicle roll bar or sport bars, extending generally therefrom and at least one cross member  20  connecting the side members  16 ,  18  substantially adjacent the rear of the front cockpit compartment indicated generally at  22 . 
     The assembly  10  generally includes a plurality of side rails, a plurality of bows, a plurality of linkages, at least one lift assist mechanism and at least one cover  11 . The assembly  10  has a pivotal portion shown generally at  62  including a lift assist assembly shown generally at  63 . The assembly  10  is operable to move the pivotal portion  62  between a closed position (to close the roof top opening of the vehicle) and an open position or “open sunroof” position (which uncovers at least the front cockpit  22  of the vehicle). Typically, the assembly  10  is further moveable between the open position and at least one top down position (which further uncovers the roof opening to create an open air experience for the rear passenger compartment) or open/stowed position. A fully stowed position where the top is retracted and collapsed against the rear cargo bed of the vehicle is also contemplated depending on the application without departure from the scope of the present invention. The present invention has additional bows, e.g., fabric management bows, with control linkages. The present invention also has a rear side rail with gas cylinders and control linkages to assist with lifting and controlling motion of the side rail assembly. 
     The plurality of bows of the assembly  10  includes at least a first bow  24  (selectively attachable to the windshield frame  14  are, e.g., via header latches to footman loops on the vehicle), a second bow  26 , a third bow  28 , a fourth bow  30  (rear bow), a first intermediate bow  32  (located between the first and second bows  24 , 26 ), and a second intermediate bow  34  (located between the second and third bows  26 , 28 ). More or less bows are contemplated depending on the application without departure from the scope of the present invention. Most preferably, at least the first and second intermediate bows  32 , 34  are fabric management bows. Preferably, the fabric management bows manage fabric of the soft top material cover during movement of the cover between the closed and open positions. The fabric management bows also minimize fabric movement when the soft panel top assembly is in the closed position, minimizes fabric movement in the closed position to cut down on noise, and manages fabric during operation between positions. 
     The assembly  10  includes at least one side rail. Most preferably, a side rail  36  (preferably, that is a front side rail) pivotally connected to a second side rail  38  (preferably, a rear side rail), on both sides of the vehicle  12 . More or less side rails are contemplated depending on the application without departure from the scope of the present invention. 
     The plurality of linkages of the assembly  10  includes a second bow pivot link  44  (connected to the front side rail  36 ), a second intermediate bow control link  46  (connected to the pivot link  44  and the rear side rail  38 ), and a second intermediate bow pivot link  48  (operably connected to the second intermediate bow  34  and rear side rail  38 ). Another assist linkage  50  is also connected to the second intermediate bow pivot link  48  and the second intermediate bow control link  46 . 
     Preferably, the first intermediate bow assembly  82  includes first and second control links  86 , 88  connected to the first intermediate bow  32 . The first control link  86  is also connected to the first side rail  36 . Preferably, the second intermediate bow assembly  34  is connected to the assist linkage  50  and second intermediate bow pivot link  48 . 
     The lift assist mechanism  63  includes a first gas strut  52  and a second gas strut  54 , e.g., first and second gas cylinders, preferably, including actuation shafts  52   a  and  54   b , respectively, received in first and second compressed air assist pneumatic cylinder bodies, cylinders  52   b  and  54   b , respectively. Preferably, the first and second gas struts  52  and  54  are operably connected in force opposition generally between the intermediate bow pivot link  48  and the second side rail  38  such that when one is compressed when the pivotal portion  62  is closed the other is extended, and vice versa. At least one first idler link  56  is connected to the first gas strut  52  and the rear side rail  38 . At least one second idler link  58  is connected to the second gas strut  54  and the second intermediate bow pivot link  48 . At least one idler link stop  60  is operably connected on the second intermediate bow pivot link  48 . 
     In the top closed position, the first gas strut  52  is fully loaded, compressed, and, the second gas strut  54  is fully unloaded, open (see  FIG.  2   ). 
     The front side rail  36  is part of a pivotal portion shown generally at  62  (e.g., see  FIG.  3   ). The assembly  10  is unlatched from the windshield header  14  at the first bow  24 . The pivotal portion  62  is then lifted and rotated rearward. The top cover management is controlled by first and second intermediate bow shown generally at  82  and  84 , including first and second intermediate bows  32  and. The pivotal portion  62  continues to rotate until the mechanism is in the open sunroof position (e.g.,  FIG.  7   ). 
     Referring more particularly to  FIGS.  4  and  5   , as the pivotal portion  62  is opened by lifting the first side bow  36 , the first gas strut  52  cylinder unloads. In doing so the cylinder applies its load through the top mechanism linkages, thereby reducing the amount of effort required to operate the top. The second gas strut  54  cylinder remains fully unloaded as it is free to rotate via the idler link  58  attached to the second intermediate bow pivot link  48  (about the pivot joint  64 ). 
     Referring more particularly to  FIG.  6   , by continuing the motion in opening the top (rotating the pivotal portion  62  further rearward), the idler link stop  60  attached to the second intermediate bow link  48  then makes contact with the second gas strut idler link  58 . After making this contact, as the motion continues, it loads up the second gas strut  54 . This loading dampens the effect of the top mass as the pivotal portion  62  moves down into the sunroof position. At the same time, first gas strut  52 , when fully unloaded, is free to rotate about a pivot joint  66  on the first idler link  56  that is attached to the rear side rail  38 . 
     Referring more particularly to  FIGS.  7  to  9   , when in the open sunroof position, the first gas strut  52  is fully unloaded, open. The second gas strut  54  is fully loaded, compressed. 
     Referring more particularly to  FIGS.  10 - 11    (and  FIG.  5    equally applicable to the rearward/forward directions), in operation to move the top from the open sunroof position and the closed position, the pivotal portion  62  is lifted and rotated forward. The top cover management is controlled by the first and second intermediate bows assemblies  82 , 84 . Continue rotating the pivotal portion until the assembly is in the closed position. Then latch to the windshield header  14 . 
     Referring more particularly to  FIGS.  10 - 11   , as the top is being closed, second gas strut  54  cylinder unloads. In doing so, the cylinder applies its load through the top mechanism linkages thereby reducing the amount of effort required to operate the top. The first gas strut  52  cylinder remains unloaded and is free to rotate via the first gas strut idler link  56 . 
     Referring more particularly to  FIG.  5   , continuing through the closing motion the first gas strut idler link  56  makes contact with a second idler stop  61  attached to the rear side rail  38 . As the mechanism continues to close, this stop  61  prevents any further rotation of the idler link  56 , thereby compressing the first gas strut  52 . The compression of the first gas strut  52  dampens the motion of the top mechanism as it closes. The second gas strut  54  is fully unloaded at this point. 
     Referring more particularly to  FIGS.  1  and  11   , preferably, a pair of rear bow lift assist, shown generally at  70 , is provided which is operably connected to the rear bow  30 , e.g., by a pair of rearmost uprights rotatably connected to the lift assist  70 , and the lift assists  70  are connected to the vehicle rear sport bars for rotational movement of the assembly  10 , including, the rear bow  30 , to the top down/open position. A pair of rear uprights  72  are also operably rotatably connected to the rear bow lift assist  70  and operably connected to the three bow  28  to set a rear upper transition height and for rotation to the assembly  10  to the top down/open position. Preferably, at least one of the rear bow lift assists  70  is a locking lift assist. A lift assist release assembly can also be provided to release the rear bow lift assist to allow rotation of the assembly  10  to the open down position. 
     Referring to the figures generally, and, more particularly, to  FIGS.  12 - 13   , preferably, the soft top assembly  10  includes at least one door rail. This provides the connection to the vehicle  12  (and can additionally provide sealing, depending on the application). Preferably, a plurality of door rails are provided. Most preferably, a door rail  80  (preferably, that is a front door rail) operably connected to the vehicle, and a second side rail  76  (preferably, a rear door rail) on both sides of the vehicle  12 . More or less door rails are contemplated depending on the application without departure from the scope of the present invention. Preferably, the first and second door rails  80 , 76  provide a water tight seal with the cover of the top assembly  10  when in the closed position. Preferably, the pair of first and second door rails  80 , 76  also provide a water tight seal against the vehicle doors, e.g., front doors and rear doors, respectively. The first and second door rails  80 , 76  are operably connected to the vehicle  12 , preferably, with at least one clamp  78 , most preferably, a plurality of clamps  78  on the first and second door rails  80 , 76 , respectively, which connect to the sport bars  16 , 18 , e.g., via mushroom knobs or other threaded fastener or fastener of any kind suitable for connecting the door rails  80 , 76  to the sport bars  16 , 18 . Any other suitable attachment feature of the pivotal portion  62  to the vehicle depending on the application is contemplated without departure from the scope of the present invention, e.g., a side rail (e.g., first side rail  36 ) rotatably connected directly to a cross member  22 , sport bar  16 , 18  or any other vehicle part. 
     Most preferably, the second door rails  76  provide a connection with the soft top mechanism, preferably, a slidably connected feature within a track  74  of the second door rails  76 , right hand and left hand door rails  76  on opposing sides of the vehicle  12 . Preferably, the track  74  is operably connected to the vehicle (both sides in a fore/aft direction), most preferably, operably connected to or integrally formed with the second door rails  76 . At least one guide roller assembly is provided on each side of the assembly  10  with a guide roller  42  that slides in the tracks  74 . The guide roller assembly includes a bracket  40  operably connected to the front or rear side rail  36 , 38 , most preferably, to the rear guide rail  76 . The bracket  40  is also operably connected to the guide roller  42 . Once the pivotal portion  62  is rotated rearward to the open sunroof position, this allows the top to be slid rearward along the track  74  to allow the assembly  10  to rotate to the top open/down position. 
     Referring to  FIGS.  1 - 13    generally, it is understood that the left side of the assembly  10  is a substantially mirror image to the right side. It is also understood that while a 4-door sport utility vehicle is illustrated, it is understood that the present invention is adaptable for a 2-door vehicle, 2-door sport utility vehicle, 4-door vehicle, 2 or 4-door SUV with extended cargo area, or any other kind of vehicle and etc, without departure from the scope of the present invention. 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence 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.