Patent Description:
In modern cars there is quest for maximizing headroom and maximizing the daylight opening in roof systems.

The features according to the preamble of claims <NUM> and <NUM> is known from <CIT> and <CIT>. The roof system disclosed therein includes a front support for the panel carrying on its inner side a panel guide into which an outward guide pin of the rear support engages. As a result, the rear support is positioned more inwardly than the front support.

It is an object of the present invention to provide a roof system having an improved headroom and/or daylight opening.

For this purpose, the roof system according to the invention has the features of the characterizing portion of claim <NUM>.

Due to the inward placement of the panel bracket guide and thus the co-operating rear support it is possible to position the guide rails more outwardly, especially in roof systems in which the panel is wider at the front than at the rear.

Preferably, the rear support is mainly stationary and is positioned substantially behind said upright flange of the guide rail.

The upright flange may be the innermost functional flange of the guide rails, especially if sunshade is integrated in the panel.

If the upright flange is the innermost functional flange of guide rail, the guide rail can be made relatively narrow, thereby further increasing the daylight opening.

An even further increase can be obtained if the lateral inner side of each guide rail includes a tapering along at least a part of its length to follow at least partly a tapered shaped of the panel, the roof system including a head liner to cover the fixed roof and frame of the roof system from below, said headliner following the tapering of the guide rails.

The guide rails may be even narrower if the upright flange borders the guide groove of a slide shoe of the front support, especially if said slide shoe is only guided in the guide groove of the upright flange, and not also in an opposite guide groove.

If the panel bracket is attached to a panel reinforcement of the panel by means of screws outside the upright flange of the guide rail, it is possible to reach the screws with a tool without being hindered by an interfering part of the guide rail or of the operating mechanism.

The slide shoe may be part of a slide shoe support which is connected to the lateral outer side of the panel bracket, which is preferably formed by a lever of the front support determining the height of a front side of the panel.

In one embodiment, the lever comprises a curve co-operating with a locking cam on the driving slide of the operating mechanism to which a drive member is connected. The shape of the curve determines whether the lever of the front support is pivoting and/or sliding.

According to another aspect of the invention according to claim <NUM>, the panel bracket guide extends more inwardly than a slide shoe of the panel front support.

If the panel front support includes a front lever and the panel rear support includes a rear lever, the rear lever is positioned more inwardly than de front lever.

The roof system according to the invention will be further elucidated with reference to the drawings showing an embodiment of the roof system by way of example only.

Firstly referring to <FIG> and <FIG>, a roof system is schematically illustrated. In a fixed roof <NUM> of a vehicle <NUM> a roof opening <NUM> is defined which can be closed (<FIG>) and opened (<FIG>) by a movable closure, here a rigid, at least partly (semi)transparent panel <NUM>, made of glass, plastic or the like. The roof assembly may include a second panel <NUM>' which is generally a fixed panel <NUM>' but may also be movable as well.

The roof system is a so-called top-loaded roof system in which a stationary part of the roof system is introduced into the roof opening <NUM> from above, is resting on the fixed roof, normally a flange <NUM> of a roof beam <NUM>, see <FIG> and <FIG>. The stationary part is attached to the fixed roof <NUM> of the vehicle by a suitable manner, preferably gluing, but also welding and bolting would be possible, depending on the materials used.

The roof system shown here is a so-called spoiler roof in which the panel is movable from its closed position upwardly (at least with its rear side) and then rearwardly to positions above the fixed roof, or in this case above rear panel <NUM>'. The operating mechanism, in particular the supports for panel <NUM>, remains mainly within the roof opening, contrary to a top slider in which rear supports of the panel slide in guide rails that extend or are extended to positions behind roof opening <NUM>.

<FIG> shows some of the components of the roof system. A frame <NUM> forms the main component of the stationary part of the roof system. In this case frame <NUM> is made from plastic material by injection moulding providing great freedom of design. It carries a panel seal <NUM> (<FIG> and <FIG>) sealing panel <NUM> from below. A guide rail <NUM> is fixed to frame <NUM> in longitudinal direction below each side edge of panel <NUM>. The length of guide rail <NUM> is such that it extends substantially from the front to the rear of roof opening <NUM>. An operating mechanism <NUM> is connected to and guided in each guide rail <NUM> and an electric motor (not shown) is capable of driving parts of operating mechanisms <NUM> through drive cables (not shown). A front and rear reinforcement <NUM>, <NUM> is fixed to frame <NUM> and to each guide rail <NUM>. A glue strip <NUM> (<FIG>) is used to attach frame <NUM> to flange <NUM> of longitudinal roof beam <NUM> and flanges of cross beams (see <FIG>).

<FIG> and <FIG> illustrate schematically one of the guide rails <NUM> and operating mechanism <NUM>. It should be kept in mind that the roof system comprises an equal guide rail <NUM> and operating system <NUM> on the opposite side, albeit configured as a mirror image. Guide rail <NUM> comprises an extrusion profile <NUM>, for example from aluminium, having one or more guide grooves. The extrusion profile <NUM> is straight or slightly bent to follow the curvature of fixed roof <NUM> of vehicle <NUM>. One guide groove <NUM> is extended to the front by an insert <NUM> including a downwardly curved portion <NUM>' of guide groove <NUM>. Guide groove <NUM> guides a front slide shoe <NUM> of a front support <NUM> of panel <NUM>, here being formed by a lever <NUM> pivotally connected on its front end to a panel bracket <NUM>. A driving slide <NUM> is attached to the drive cable (not shown) and is controlling lever <NUM> on the one hand and temporarily driving rear support <NUM> through an elongate connecting member <NUM>.

Driving rear support <NUM> means moving a lever mechanism <NUM> such that rear support <NUM> moves the rear side of panel <NUM> upwardly to a venting position. The lever mechanism <NUM> includes a fixed part <NUM> which is attached to extrusion profile <NUM> of guide rail <NUM>. The upward portion of fixed part <NUM> is positioned more inwardly than lever <NUM> of front support <NUM>. Fixed part <NUM> comprises pivot holes <NUM> for lower pivot <NUM> of lever <NUM>. An upper pivot <NUM> of lever <NUM> is connected to slide claw <NUM> which is slidably supporting panel bracket <NUM> through a panel bracket guide <NUM> thereof. The slide claw <NUM> comprises a guide pin <NUM> on its outer side engaging a guide slot <NUM> of a sliding guide <NUM>. This sliding guide <NUM> is pivotally connected to a slide shoe <NUM> at the rear end of connecting member <NUM>. Connecting member <NUM> and slide shoe <NUM> are guided in a guide groove <NUM> of guide rail <NUM>. Guide slot <NUM> of sliding guide <NUM> includes a substantially horizontal slot portion <NUM>' and a substantially vertical locking slot portion <NUM>" connecting to the front end of slot portion <NUM>'. Sliding guide <NUM> comprises on its outer side a guide pin <NUM> engaging a guide slot <NUM> in fixed part <NUM>. This guide slot <NUM> includes a substantially horizontal front slot portion <NUM>', a rearwardly and upwardly inclined main slot portion <NUM>" and a substantially horizontal rear slot portion <NUM>‴.

Connecting member <NUM> is either locked to driving slide <NUM> or to a locking insert <NUM> of guide rail <NUM>. For this purpose, a locking lever <NUM> is pivotally attached to the front end of connecting member <NUM>. Locking lever <NUM> carries two opposite locking pins <NUM> and <NUM>, locking pin <NUM> being in engagement with a locking slot <NUM> in locking insert <NUM> and locking pin <NUM> engaging a locking slot <NUM> in driving slide <NUM>. Locking slot <NUM> includes a horizontal front releasing portion <NUM>' and vertical rear locking slot portion <NUM>". A spring <NUM> loads locking lever <NUM> upwardly. Locking slot <NUM> in driving slide <NUM> is forwardly and upwardly inclined and is open at the front end, such that driving slide <NUM> may be released from locking lever <NUM> as soon as locking pin <NUM> has arrived at the upper end of rear locking slot portion <NUM>" in locking insert <NUM>.

Lever <NUM> of front support <NUM> is connected to driving slide <NUM> by a locking cam <NUM> on driving slide <NUM> and locking curve <NUM> on lever <NUM>. Locking curve <NUM> includes a substantially horizontal curve portion <NUM>' and a substantially vertical curve portion <NUM>".

<FIG> shows in a plan view more clearly that parts of rear support <NUM> are positioned more inwardly than the parts of front lever <NUM>, while connecting member <NUM> with its rear slide shoe <NUM> is situated most outwardly in a guide groove <NUM>. As a result, panel bracket <NUM> with panel bracket guide <NUM> are positioned inwardly of a flange <NUM> of guide rail <NUM> (<FIG>, <FIG>), while lever <NUM> of front support <NUM> is positioned outwardly of said flange <NUM>. Also rear lever <NUM> of rear support <NUM> is positioned more inwardly than front lever <NUM> of front support <NUM>. The flange <NUM> comprises guide groove <NUM> for front slide shoe <NUM> of lever <NUM> and is the innermost functional flange of guide rail <NUM>. The reason for this is that this roof system does not have a rollo or another sunshade which is normally guided in the innermost guide groove of guide rail <NUM>. A sunshade may be integrated in panel <NUM>, either an integrated mechanical sunshade or electrochromic glass. Due to this integrated sunshade, guide rail <NUM> may be made narrower and thus a wider daylight opening, and more headroom is created.

<FIG> also shows that connecting member <NUM> is positioned relatively outwardly in guide rail <NUM>. However, this connecting member <NUM> hardly extends above guide rail <NUM> so that it does not hinder an outward placement of guide rail <NUM> partly below frame <NUM>. Sliding guide <NUM> of rear support <NUM>, which builds higher and moves upwardly, is positioned more inwardly, made possible by slide shoe <NUM> which connects connecting member <NUM> and sliding guide <NUM>, but also has a low profile.

From <FIG> it is clear that frame <NUM> extends above guide rail <NUM> in some places, especially at the rear end where tapered frame <NUM> is narrower. It is even extending above guide groove <NUM> for slide shoe <NUM> of connecting member <NUM>.

<FIG> and <FIG> illustrate the operation of operating mechanism <NUM>.

In <FIG>, <FIG>, panel <NUM> is in its closed position within roof opening <NUM>. In this closed position lever <NUM> of front support <NUM> is in its lower front position with its front slide shoe <NUM> at the lower front end of guide groove <NUM> in insert <NUM> of guide rail <NUM>. Locking pin <NUM> is at the front end of locking slot <NUM> in locking insert <NUM> and locking pin <NUM> is at the rear end of locking <NUM> in driving slide <NUM>.

At rear support <NUM>, guide pin <NUM> of sliding guide <NUM> is in front slot portion <NUM>' of guide slot <NUM>. Guide pin <NUM> of sliding claw <NUM> is at the rear bottom end of guide slot <NUM> and lever <NUM> is in is forward and downward position.

In <FIG> and <FIG>, panel <NUM> has been moved into its rearwardly and upwardly inclined venting position. To obtain this position, driving slide <NUM> has been moved a distance rearwardly such that locking pin <NUM> of locking lever <NUM> has been moved along rearwardly through releasing slot portion <NUM>' up to vertical locking slot portion <NUM>" (<FIG>). Through crossing slot portion <NUM>' in locking insert <NUM> and slot <NUM> in driving slide <NUM>, locking pin <NUM> is in its lower position in locking slot <NUM> and therefore locking lever <NUM> and connecting member <NUM> are locked to driving slide <NUM> and move along. Consequently, sliding guide <NUM> is moved rearwardly by connecting member <NUM> and pivots upwardly due to guide pin <NUM> moving upwardly in inclined slot portion <NUM>" in fixed part <NUM>. As a result of the upward and rearward movement of sliding guide <NUM> guide pin <NUM> of lever claw slide <NUM> of rear support <NUM> is moved upwardly and therefore lever <NUM> pivots upwardly and rearwardly thereby lifting the rear side of panel bracket <NUM> and panel <NUM> upwardly. Claw slide <NUM> slides along with guide pin <NUM> of lever <NUM> a short distance rearwardly along panel bracket guide <NUM>.

<FIG> and <FIG> show the rearward open position of panel <NUM>. Locking pin <NUM> is moved into vertical locking portion <NUM>" and kept there by spring <NUM>. Locking pin <NUM> locks locking lever <NUM> to locking insert <NUM> of guide rail <NUM>, so that connecting member <NUM> and therefore rear support <NUM> is locked in its position. The upward movement of locking pin <NUM> and locking lever <NUM> is caused by locking pin <NUM> which is moved up through locking slot <NUM> (<FIG>) and to its open front end so that locking pin <NUM> may be disengaged from locking slot <NUM> and thus allowing driving slide <NUM> to move rearwardly without taking along locking lever <NUM> and connecting member <NUM>.

Lever <NUM> of front support <NUM> is moved rearwardly by driving slide <NUM> when locking cam <NUM> has arrived at vertical locking portion <NUM>" of locking curve <NUM> in lever <NUM> allowing lever <NUM> to pivot upwardly due to the displacement of front slide shoe <NUM> in curve <NUM>' of guide groove <NUM> (not shown here). Lever <NUM> is locked against pivoting movements due to engagement of front slide shoe <NUM> in horizontal guide groove <NUM> of guide rail <NUM> and engagement of locking cam <NUM> in vertical locking curve portion <NUM>".

When connecting member <NUM> is uncoupled from driving slide <NUM> when panel <NUM> is in its venting position a continued rearward movement of driving slide <NUM> will slide lever <NUM> of front support <NUM> rearwardly thereby moving panel bracket <NUM> rearwardly and panel bracket guide <NUM> thereof will be allowed to slide along slide claw <NUM> of rear support <NUM>, so that panel <NUM> moves with respect to rear support <NUM>.

<FIG> show the relationship between parts in different cross-sections. It also shows some further parts, not shown in <FIG>. The area between panel seal <NUM> and a second panel seal <NUM> may act as a water drain collecting water seeping in beyond panel <NUM> and may drain water towards the area above flange <NUM> of roof beam <NUM> which can drain water to the outside of vehicle <NUM>.

<FIG> illustrates how front slide shoe <NUM> engages guide groove <NUM> in guide rail insert <NUM>. This insert <NUM> projects downwardly through a hole in front reinforcement <NUM>. Further it is shown that lever <NUM> and panel bracket <NUM> are connected to each other in a position above insert <NUM>/flange <NUM>, so that panel bracket <NUM> extends on the inner side of insert <NUM>/flange <NUM> and lever <NUM> extends mainly on the outer side. This inward position of panel bracket <NUM> and co-operating rear support enables an outward position of guide rail <NUM> thereby improving headroom and daylight opening.

<FIG> further shows an outer panel seal <NUM> sealing against the circumferential edge of panel <NUM> in its closed position. A cover strip <NUM> covers the area between the outer panel seal <NUM> and a roof skin <NUM> of fixed roof <NUM>.

<FIG> shows driving slide <NUM> next to a cable guide <NUM> for a drive cable (not shown) attached to the driving slide <NUM>. Flange <NUM> containing guide groove <NUM> is shown, bordered on the inside by panel bracket <NUM> and on the outside by lever <NUM>. It further shows locking insert <NUM> in guide groove <NUM> and carrying windings of spring <NUM>. On the inside of the locking insert <NUM> locking lever <NUM> is located. Below panel seal <NUM>, there is a connection between front reinforcement <NUM>, extrusion profile <NUM> of guide rail <NUM> and frame <NUM>. This connection is on the outer side of guide rail <NUM> and is accomplished by means of a bolt <NUM> engaging a threaded hole <NUM> in a distance holder <NUM> of frame <NUM>.

In the cross-section of <FIG>, it is visible that guide groove <NUM> of connecting member <NUM> is now substantially below panel seal <NUM> due to the tapered shape of roof opening <NUM> and due to the outward position of guide rail <NUM> below frame <NUM>. It is also shown that a connection between panel bracket <NUM> and a reinforcement <NUM> below panel <NUM> is on the inside of flange <NUM>. This has the advantage that there is no interference for a tool for screw <NUM> to attach reinforcement <NUM> to panel bracket as screw <NUM> can easily be reached from the interior of the vehicle.

<FIG> illustrates the connection between slide shoe <NUM> of connecting member <NUM> to sliding guide <NUM> of rear support <NUM>. Due to the inward position of sliding guide <NUM> substantially in line with guide groove <NUM> it is possible to allow guide groove <NUM> and cable guide <NUM> to extend in the area below panel seal <NUM>. Panel bracket <NUM> and panel bracket guide <NUM> are positioned still inwardly of flange <NUM>.

In the cross-section of <FIG> panel seal <NUM> is positioned closer to the centre of the vehicle and roof system compared to that of <FIG> due to the tapered shape of fixed roof <NUM>, roof opening <NUM> and panel <NUM>. As a result, guide groove <NUM> is now extending below the area between panel seal <NUM> and outer panel seal <NUM>. Also cable guide <NUM> in guide rail <NUM> is now slightly more inwardly with respect to panel seal <NUM> compared to the cross-section of <FIG>.

<FIG> shows a cross-section near the rear end of guide rail <NUM>, in particular beyond extrusion profile <NUM> thereof. Guide slot <NUM> of fixed part <NUM> is inwardly of panel seal <NUM> and frame <NUM>, while a horizontal base portion <NUM>' of fixed part <NUM> extends below frame <NUM> and panel seal <NUM>. Slide claw slide <NUM> engages panel bracket guide <NUM>. Rear reinforcement <NUM> extends below rear support <NUM>.

<FIG> and a comparison of <FIG> show that the inner side of extrusion profile <NUM> of guide rail <NUM> is tapered in its front half. This is done by gradually removing a portion of an inner flange <NUM> of extrusion profile <NUM> in forward direction. As front support <NUM> of operating mechanism <NUM> is positioned more outwardly compared to the moving parts of rear support <NUM> it is possible to remove a part of said inner flange <NUM> of guide rail <NUM> such that it more or less follows the tapering of the roof. If then also a roof lining <NUM> of the vehicle, which covers the roof system from below, is following the tapering (not shown here) some additional head room and daylight opening is created.

It will be clear from the foregoing description that the invention provides a roof system enabling a very wide daylight opening and additional headroom due to the outward placement of guide rail <NUM>. This is made possible by the operating mechanism of which the upwardly moving or projecting parts of rear support <NUM> are positioned more inwardly towards a longitudinal centre line of the roof system than front support <NUM>. This makes this operating mechanism very suitable for use with tapered fixed roofs <NUM> of vehicles <NUM> and tapered panels <NUM> of the roof systems mounted therein.

In this description horizontal should generally be understood as parallel to guide rail <NUM> and vertical generally means perpendicularly to guide rail <NUM>. As extrusion profile <NUM> of guide rail <NUM> is slightly curved, horizontal and vertical may vary along the length of guide rail <NUM>.

Claim 1:
Roof system for a vehicle (<NUM>) having a roof opening (<NUM>) in its fixed roof (<NUM>), comprising a stationary part (<NUM>, <NUM>) configured to be attached to the fixed roof, a panel (<NUM>) movably supported on the stationary part and configured to close the roof opening in its closed position and to be moved at least rearwardly to an opened position in which the roof opening is at least partly opened, the stationary part (<NUM>, <NUM>) including guide rails (<NUM>) extending in longitudinal direction substantially parallel to opposite sides of the roof opening (<NUM>), said guide rails slidably supporting an operating mechanism (<NUM>)for the panel and includes guide grooves (<NUM>, <NUM>) bordered by guide flanges, the operating mechanism including a driving slide (<NUM>), a panel front support (<NUM>) and a panel rear support (<NUM>) movable by means of the driving slide, the rear support being connected to a panel bracket guide (<NUM>) of a panel bracket (<NUM>) extending in longitudinal direction alongside a corresponding edge of the panel, said panel bracket guide being slidably in engagement with the panel rear support (<NUM>) so as to enable the panel to slide with respect to the rear support when the front support (<NUM>) is driven by the driving slide (<NUM>), characterized in that the panel front support (<NUM>) is in engagement with a guide rail groove (<NUM>) on the outer side of an upright flange (<NUM>) of each guide rail (<NUM>) while the panel bracket guide (<NUM>) extends mainly on the other, inner side of said upright flange.