Patent Publication Number: US-2013247348-A1

Title: Sunroof drain tube assembly and method

Description:
BACKGROUND 
     The subject disclosure generally relates to sunroof drain tubes in vehicles, and particularly relates to a sunroof drain tube installation assembly and method for installing and/or replacing a sunroof drain tube in a vehicle. 
     It is known that sunroof drain tubes in vehicles occasionally need to be replaced due to wear or leaks. Typically, sunroof drain tubes have an upper end fluidly connected to a gutter or channel area disposed about a periphery or beneath a sunroof on a vehicle and a lower end disposed at a location to which it is desirable to direct drainage from the sunroof. In some applications, the sunroof drain tube passes along or within the A-pillar on the vehicle. Heretofore, the space in which a sunroof drain tube was installed in such a pillar was large enough that the old drain tube could be easily removed and replaced. In particular, the old sunroof drain tube could be grasped in view of the plentiful space surrounding the tube and pulled out of the pillar. 
     As vehicle designs progress, it is becoming increasingly difficult to remove the sunroof drain tube from a vehicle pillar using conventional methods. In particular, it can be difficult because the sunroof drain tube is a blind installation within the pillar and thus removal requires work on portions of the sunroof drain tube that cannot be seen. Additionally, further structural components (e.g., bulkheads) are often added to the pillar in newer vehicle designs, which increases the difficulty in removing the sunroof drain tube. Still further, the pillar can receive a damping treatment, such as application of spray foam, thus increasing the difficulty in removing the sunroof drain tube from the pillar. Spray foam may be used to improve noise and/or vibration concerns for the vehicle. When spray foam is used, there is essentially no clearance around the sunroof drain tube and thus grasping of the sunroof drain tube, as was used in conventional removal techniques, is precluded. Moreover, spray foam is generally a relatively soft material and can be easily damaged if handled too roughly as might occur when applying conventional sunroof drain tube removal techniques. 
     SUMMARY 
     According to one aspect, a method is provided for installing a sunroof drain tube in a vehicle. In the method, a drain tube installation tool is provided having an elongated flexible portion with a first end and a second end, and a stopper disposed at the second end of the elongated flexible portion. The first end of the elongated flexible portion is threaded through the sunroof drain tube to be installed on the vehicle. The first end of the elongated flexible portion is also threaded through a sunroof drain tube passageway defined on the vehicle. The first end of the elongated flexible portion is pulled to forcibly install the sunroof drain tube into the sunroof drain tube passageway. The stopper forcibly causes the sunroof drain tube to move into the sunroof drain tube passageway as the first end of the elongated flexible portion is pulled. 
     According to another aspect, a sunroof drain tube installation assembly is provided for installing a sunroof drain tube in a vehicle. The sunroof drain tube installation assembly includes an elongated flexible wire having a first end and a second end, a stopper disposed at the second end of the elongated flexible wire, and a sunroof drain tube to be installed on the vehicle. The elongated flexible wire has a diameter smaller than an inner diameter of the sunroof drain tube to allow the first end of the elongated flexible wire to be threaded into the sunroof drain tube, and has an axial length greater than an axial length of the sunroof drain tube to allow the first end of the elongated flexible wire to be threaded through the sunroof drain tube. The stopper is sized so as to have a radial dimension greater than the inner diameter of the sunroof drain tube to thereby prevent the second end of the elongated flexible wire from passing into the sunroof drain tube. 
     According to a further aspect, a method for replacing a sunroof drain tube in a vehicle is provided. In accordance with the method, a distal end of a wire portion of a drain tube installation tool is inserted into and through a replacement sunroof drain tube. The distal end of the wire portion is also inserted into and through an installed sunroof drain tube on the vehicle. The distal end of the wire portion is pulled so that a stopper of the drain tube installation tool disposed at an opposite end of the wire portion abuts an end of the replacement sunroof drain tube. The distal end of the wire portion is further pulled so that the replacement sunroof drain tube displaces the installed sunroof drain tube on the vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view, partially in cross section, of a sunroof drain tube installation assembly including an installation tool for installing a replacement sunroof drain tube in place of a sunroof drain tube installed in the A-pillar of a vehicle. 
         FIG. 2  is a perspective view of the sunroof drain tube installation tool, which includes an elongated flexible wire and a stopper. 
         FIG. 3  is a schematic perspective, partially in cross section, showing only the installed sunroof drain tube installed in the A-pillar of a vehicle for draining a sunroof gutter area of the vehicle. 
         FIG. 4  is a view similar to  FIG. 1 , but showing the elongated wire of the drain tube installation tool threaded through both the replacement sunroof drain tube and the installed sunroof drain tube on the vehicle. 
         FIG. 5 . Is another view similar to  FIG. 4 , but showing a first distal end of the elongated flexible wire being pulled such that the replacement sunroof drain tube is beginning to forcibly displace the installed sunroof drain tube within the vehicle. 
         FIG. 6  is yet another view similar to  FIG. 4 , but showing the replacement sunroof drain tube installed in the vehicle and fully displacing the originally installed sunroof drain tube, and further showing the drain tube installation tool being removed from the sunroof drain tubes. 
         FIG. 7  is a block diagram illustrating a method for installation/replacing a sunroof drain tube on a vehicle. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for limiting same,  FIG. 1  shows a sunroof drain tube installation assembly  10  for installing and/or replacing a sunroof drain tube in a vehicle V. More particularly, and with additional reference to  FIG. 2 , the illustrated sunroof drain tube installation assembly  10  includes a drain tube installation tool  12 . The drain tube installation tool  12 , and thus the drain tube installation assembly  10 , includes an elongated flexible portion or wire  14  having a first end  14   a  and a second end  14   b , and a stopper  16  disposed at the second end  14   b  of the elongated flexible wire  14 . As shown in the illustrated embodiment, the elongated flexible wire  14  can be a braided wire having a cap  18  at the first end  14   a  to facilitate threading of the elongated flexible wire  14  into a sunroof drain tube, as will be described in more detail below. The cap  18  can function to keep the first end  14   a  of the flexible wire  14  from unbraiding or fraying. 
     The assembly  10  can further include a sunroof drain tube  20  that is to be installed on the vehicle V. As shown, the elongated flexible wire  14  has a diameter smaller than an inner diameter of the sunroof drain tube  20  to allow the first end  14   a  of the elongated flexible wire  14  to be threaded into the sunroof drain tube  20 . Additionally, the elongated flexible wire  14  has an axial length greater than an axial length of the sunroof drain tube  20  to allow the first end  14   a  of the elongated flexible wire  14  to be threaded completely through the sunroof drain tube  20  as shown in  FIG. 1 . Still further, and as shown in the illustrated embodiment, the stopper  16  can be sized so as to have a radial dimension greater than the inner diameter of the sunroof drain tube  20  to thereby prevent the second end  14   b  of the elongated flexible wire  14  from passing into and through the sunroof drain tube  20 . 
     With additional reference to  FIG. 3 , a sunroof drain tube  30  is shown installed on the vehicle V and can be referred to as an installed sunroof drain tube. In particular, the installed sunroof drain tube  30  is shown installed through a pillar  32  on the vehicle V. The pillar  32  can be an A-pillar extending along the vehicle&#39;s windshield  34  from a location at or adjacent an intersection between a longitudinal roof rail  36  and a lateral roof rail  38 . The pillar  32  can extend down from this intersection along a lateral edge of the windshield  34  as is known and understood skilled in the art. Alternatively, the pillar  32  could be some other pillar on the vehicle V. The installed sunroof drain tube  30  can be fluidly connected to a gutter area  40  on the vehicle V, such as the illustrated gutter area  40  defined by the roof rails  36 ,  38  in the illustrated embodiment. As is known and understood by those skilled in the art, the gutter area  40  can be disposed about a periphery of a sunroof (not shown) of the vehicle V and/or about a periphery of a sunroof opening  42  for such a sunroof. It will become apparent, at least to those skilled in the art, that the sunroof, sunroof opening and vehicle need not be as shown in the illustrated embodiment as the showings are merely exemplary. 
     In the illustrated embodiment, a drainage aperture  44  is defined in the gutter area  40  and is fluidly connected to the installed sunroof drain tube  30 . More particularly, as shown, a drain member or grommet  46  can be disposed at the location of the drainage aperture  44  for providing a structure to which a first or upper end  30   a  of the installed sunroof drain tube  30  can be connected to the aperture  44  and thereby to the gutter area  40 . As shown, the sunroof drain tube  30  can extend through the pillar  32  to a location spaced apart vertically from the gutter area  40  and, in the illustrated embodiment, further extends down the vehicle to a location adjacent an underside  48  of the vehicle V. In particular, in the illustrated embodiment, a second or lower end  30   b  of the installed sunroof drain tube  30  can be connected to a grommet  50  secured adjacent the underside  48  of the vehicle V for directing fluid (e.g., rain water) from the gutter area  40  through the drain tube  30  and out beneath the vehicle V via the grommet  50 . 
     In the illustrated embodiment, the installed sunroof drain tube  30  passes through an aperture  52  defined at least through spray foam insulation  54  disposed within the pillar  32 , the spray foam insulation advantageously reducing noise and vibrations within the vehicle V. As shown, the diameter of the aperture  52  can substantially match an outer diameter of the installed sunroof drain tube  30  to minimize radial gaps therebetween. Additionally, in the illustrated embodiment, the installed sunroof drain tube  30  can pass through another aperture  56  defined through additional spray foam insulation  58  wherein again the diameter of the aperture  56  substantially matches the outer diameter of the installed sunroof drain tube  30  to minimize radial gaps therebetween. In the illustrated embodiment, this additional spray foam insulation  58  is disposed within the A-pillar  32  at a location spaced vertically below the windshield  34 . It is to be appreciated, however, that spray foam insulation or other tightly packed surrounding elements can be disposed within the pillar  32  at any location therealong or along the entire longitudinal extent of the pillar  32 . The apertures  52 ,  56  together define and/or form a sunroof drain tube passageway within the vehicle V, and particularly within the pillar  32  of the vehicle V. The installed sunroof drain tube  30  is fit complimentarily within this drain tube passageway such that there is no clearance area disposed radially about the installed sunroof drain tube  30 , at least along portions of the drain tube  30 . 
     Returning reference to  FIG. 1 , it is noted that the sunroof drain tube  20  can be a replacement sunroof drain tube that is used to replace the installed sunroof drain tube  30 . Replacement of the already installed sunroof drain tube  30  might be necessary due to wear or leaks related to the installed sunroof drain tube  30 . As noted, particularly in relation to the spray foam  54 ,  58 , it may be difficult to gain access to the sunroof drain tube  30 , particularly along its entire length and therefore it may be difficult to remove the installed sunroof drain tube  30  through conventional techniques (e.g., opening the pillar  32  and grasping the installed sunroof drain tube  30  at points along its entire longitudinal length to remove same from the pillar  32 ). Accordingly and as will be described in more detail below, the assembly  10 , including the drain tube installation tool  12  and the replacement drain tube  20 , can be used to both remove the installed sunroof drain tube  30  and install the replacement drain tube  20  within the vehicle V. 
     In this regard, the replacement sunroof drain tube  20  can have an outer diameter that is substantially the same as the outer diameter of the installed sunroof drain tube  30  on the vehicle V that is to be replaced by the replacement sunroof drain tube  20 . Additionally, the replacement sunroof drain tube  20  can have a length substantially the same as the installed sunroof drain tube  30 . These dimensional matches can facilitate displacement of the installed sunroof drain tube  30  by the replacement sunroof drain tube  20  when the elongated flexible wire  14  is serially threaded the replacement sunroof drain tube  20  and the installed sunroof drain tube  30  and the first end of the wire  14  then pulled, as is shown in  FIGS. 4-6 . 
     A method for installing and/or replacing a sunroof drain tube in a vehicle will now be described with specific reference to  FIG. 7 . In particular, the method will be described in association with the sunroof drain tube installation assembly  10  described hereinabove, though this is not required. In the method at S 100 , the drain tube installation tool  12 , such as shown in  FIG. 2 , can be provided having the elongated flexible wire  14  with first end  14   a  and second end  14   b , and the stopper  16  disposed at the second end  14   b  of the wire  14 . As shown in  FIG. 1 , the first or distal end  14   a  of the wire  14  is threaded or inserted into and through the sunroof drain tube  20  at S 102 . After threading/inserting into and through the sunroof drain tube  20  at S 102 , the first end  14   a  of the wire  14  can be threaded through a sunroof drain tube passageway defined on the vehicle V at S 104 . The passageway can be the space defined in the pillar  32  in which the installed sunroof drain tube  30  resides and/or the portion thereof defined through components within the pillar  32 , such as the apertures  52 ,  56 . 
     In particular, when the sunroof drain tube  30  is already installed on the vehicle V, the first or distal end  14   a  of the wire  14  can be inserted in S 104  into and through the installed sunroof drain tube  30  on the vehicle V as shown in  FIG. 4 . Thus, threading/inserting the first end  14   a  of the wire  14  into and through the passageway of the vehicle V can encompass threading/inserting the wire  14  into and through the installed sunroof drain tube  30 . Prior to such threading of the first end  14   a  of the wire  14  through the installed sunroof drain tube  30 , the first upper end  30   a  of the installed sunroof drain tube  30  can be disconnected from the drain grommet  46  as shown in  FIG. 1 . Likewise, the second lower end  30   b  of the installed sunroof drain tube  30  can be disconnected from the drain grommet  50  as also shown in  FIG. 1 . Once the wire  14  is inserted, in S 106 , the distal end  14   a  is pulled as shown in  FIG. 4  so that the stopper  16  of the drain tube installation tool  12  abuts the end  20   a  of the replacement sunroof drain tube  20 . 
     The distal end  14   a  can then be further pulled in S 108  as shown in  FIG. 5  so that the replacement sunroof drain tube  20  displaces the installed sunroof drain tube  30  on the vehicle V, or otherwise occupies the sunroof drain tube passageway defined through the pillar  32 . Such pulling of the first end  14   a  of the wire  14  results in a forcible install of the sunroof drain tube  20  into the sunroof drain tube passageway. In particular, the stopper  16  forcibly causes the sunroof drain  20  to move into the sunroof drain tube passageway of the pillar  32  as the first end  14   a  of the wire  14  is pulled. As shown, a tool  62  can be used to facilitate such pulling of the end  14   a  of the wire  14 , though it will be appreciated that tools other than that illustrated can be used. Specifically, pulling of the wire  14  causes a leading end  20   b  of the replacement sunroof drain tube  20  to abut the upper end  30   a  of the installed sunroof drain tube  30  and forcibly pushes the installed sunroof drain tube  30  from the installed position illustrated in  FIGS. 1 and 3  on the vehicle V. The distal end  14   a  of the wire  14  is further pulled until the installed sunroof drain tube  30  is fully removed from the vehicle V and the replacement sunroof drain tube  20  occupies the passageway previously occupied by the installed sunroof drain tube  30 . 
     After installation, and as shown in  FIG. 6 , the wire  14  and thus the tool  12  can be removed from the replacement sunroof drain tube  20  and the installed sunroof drain tube  30  in S 110 . In particular, the drain tube installation tool  12  can be removed after the sunroof drain tube  20  is installed into the sunroof drain tube passageway by pulling the stopper  16  away from the sunroof drain tube passageway until the elongated wire  14  is removed therefrom. When displacing an installed sunroof drain tube, such as tube  30 , the installation tool  12  is removed by pulling the stopper  16  until the wire  14  is removed from both sunroof drain tubes  20 ,  30 . 
     Thereafter, the first upper end  20   a  of the sunroof drain tube  20  can be connected to the sunroof drain  44  and the second lower end  20   b  of the sunroof drain tube  20  can be connected to the drain grommet  50  spaced apart from the sunroof drain  44 . In particular, the end  20   a  of the tube  20  can be fluidly connected to the sunroof gutter or gutter area  40  on the vehicle V and likewise the second, opposite end  20   b  can be fluidly connected to the drainage grommet  50  vertically spaced below the sunroof gutter  40  on the vehicle V. Advantageously, the installation of the sunroof drain tube  20  (and displacement of the installed sunroof drain tube  30 ) can be done relatively easy and in a short period of time. Further, removal of the installed sunroof drain tube  30  and installation of the replacement sunroof drain tube  20  can occur without damaging the foam  54 ,  58 . 
     It will be appreciated that various of the above-disclosed and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.