BACKGROUND AND SUMMARY OF THE INVENTION

This invention relates generally to sunroofs for automotive vehicles and more specifically to a spoiler type sunroof.

There are two main types of conventional automotive vehicle sunroofs. The first type retracts a metal or glass panel from a closed position, generally flush with a stationary roof, to an open position below the stationary roof. This below-roof open position provides improved exterior vehicle aesthetics.

The second common type of sunroof is known as a spoiler sunroof which retracts the moving roof panel from the closed and flush position to an open position at least partially above the exterior surface of the stationary roof. The advantage of spoiler sunroof constructions is the ease of packaging in vehicles having relatively small stationary roofs and having limited interior head room space. Most spoiler sunroofs employ a camming drive mechanism with pins riding along inclined slots for raising and lowering the sunroof panel. Examples of such driving mechanisms are disclosed in U.S. Pat. No. 5,288,125 entitled "Open Roof Construction for a Vehicle" which issued to Huyer on Feb. 22, 1994. Various scissor linkage arrangements have also been employed in traditional spoiler sunroofs. For example, reference should be made to U.S. Pat. Nos. 4,730,868 and 4,688,848, both of which are entitled "Sliding Roof for Automobiles" and issued to Niwa on Mar. 15, 1988 and Aug. 25, 1987, respectively. Japanese Patent Publication No. 2-299927, published on Dec. 12, 1990, and German Patent Publication No. 32 11 519 A1, published on Oct. 6, 1983, also disclose other known scissor linkage arrangements for sunroofs. However, these types of conventional sunroofs often prevent linear movement of the complete scissor linkage assembly or they employ significantly elongated and, thus, difficult to package linkages.

In accordance with the present invention, a preferred embodiment of a spoiler sunroof for use in an automotive vehicle includes a scissor linkage assembly and a supplemental linkage. In another aspect of the present invention, lower pivots of the scissor linkage assembly and supplemental linkage are all linearly movable when a sunroof panel is moved from a vent position to an open position. A further aspect of the preferred embodiment of the present invention does not employ camming slots and cam follower pins to raise and lower the sunroof panel relative to a stationary track such that the lower linkage pivots are generally prevented from vertically moving. Still another aspect of the present invention moves a front linkage and one linkage of the scissor linkage assembly rearward while maintaining a second linkage of the scissor linkage assembly in a stationary fore and aft position, thereby moving the sunroof panel and associated lifting bracketry from a closed position to a vent position. In yet a further embodiment of the present invention, a linearly movable locking structure locks and unlocks from a pair of undercut locks stationarily mounted to each track. A method of operating the sunroof of the present invention is also provided.

The spoiler sunroof of the present invention is advantageous over conventional sunroofs in that the scissor arm and non-camming drive mechanism of the present invention resist collapsing and do not suffer from the usual electric motor amperage spikes commonly associated with inclined camming devices having high frictional resistance. Furthermore, the present invention is advantageous by employing small length and compact linkages which do not need to be moved or secured below the rear stationary roof, thereby allowing for easier aftermarket installation and less head room intrusion inside the automotive vehicle. The lock configuration of the present invention is advantageous over traditional devices in that the present invention promotes front and rear sunroof panel locking through a single linear motion such as to simplify part construction, actuation and locking performance. 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 top elevational view showing the preferred embodiment of a spoiler sunroof of the present invention relative to a stationary automotive vehicle roof;

FIG. 2 is a cross sectional view, taken along line 2--2 of FIG. 1, showing the preferred embodiment spoiler sunroof disposed in a closed position;

FIG. 3 is a cross sectional view, similar to that of FIG. 2, showing the preferred embodiment spoiler sunroof disposed in a vent position;

FIG. 4 is a cross sectional view, similar to that of FIG. 2, showing the preferred embodiment spoiler sunroof disposed in an open position;

FIG. 5 is an enlarged and fragmentary cross sectional view, similar to that of FIG. 2, showing the preferred embodiment spoiler sunroof disposed in the closed position;

FIG. 6 is a cross sectional view taken along line 6--6 of FIG. 5 showing the preferred embodiment spoiler sunroof disposed in the closed position;

FIG. 7 is a perspective view showing a portion of the preferred embodiment spoiler sunroof disposed in the closed position;

FIG. 8 is a cross sectional view, taken along line 8--8 of FIG. 5, showing the preferred embodiment spoiler sunroof;

FIG. 9 is a cross sectional view, taken along line 9--9 of FIG. 5, showing the preferred embodiment spoiler sunroof;

FIG. 10 is a cross sectional view, taken along line 10--10 of FIG. 5, showing the preferred embodiment spoiler sunroof;

FIG. 11 is an enlarged and fragmentary cross sectional view like that of FIG. 5, showing the preferred embodiment spoiler sunroof disposed in the closed and unlocked position;

FIG. 12 is an enlarged and fragmentary cross sectional view like that of FIG. 11, showing the preferred embodiment spoiler sunroof disposed in the closed position and a locking shoe disposed in a disengaged position;

FIG. 13 is an enlarged and fragmentary cross sectional view like that of FIG. 3, showing the preferred embodiment spoiler sunroof disposed in the vent position;

FIG. 14 is an enlarged and fragmentary cross sectional view, like that of FIG. 4, showing the preferred embodiment spoiler sunroof in the open position;

FIG. 15 is a perspective view showing a portion of the preferred embodiment spoiler sunroof disposed in the open position;

FIG. 16 is a perspective view, taken opposite that of FIG. 15, showing a portion of the preferred embodiment spoiler sunroof disposed in the open position.

FIG. 17 is a diagrammatic side view, similar to FIG. 5, showing a portion of the preferred embodiment spoiler sunroof disposed in the closed and locked position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of a spoiler sunroof 21 of the present invention is shown in FIGS. 1-4. Spoiler sunroof 21 is used in an automotive vehicle and includes a slightly curved, glass sunroof panel 23, a pair of extruded aluminum tracks 25, an upper frame 27 and a lower frame 29. Upper and lower frames 27 and 29, respectively, are preferably made from Zytel.RTM. plastic which can be obtained from E.I. DuPont Co. Lower frame 29 sandwiches a stationary sheet metal roof 31 against upper frame 27, while a bulb-like weatherstrip 33 is affixed to upper frame 27. A fractional horsepower, direct current, electric motor 35 and associated mounting bracket are secured to a lower side of upper frame 27. A pair of conventional cables 37 (see FIG. 8) are selectively pushed or pulled within guide tubes 39, return tubes held in slot 40 and passageways 41 (also see FIG. 8) of tracks 25 by selective rotation of a driving gear 43 actuated by electric motor 35. Cables 37 are longitudinally rigid but laterally flexible. Furthermore, a sunroof opening is defined by an inner edge of upper frame 27. Frame 27, as well as tracks 25, are ideally suited for aftermarket as well as original equipment factory installations since they can be simply installed from above into the stationary roof opening with minimal intrusion into the passenger compartment below the generally horizontal plane of stationary roof 31.

The structure of the present invention sunroof 21 can best be observed in FIGS. 5-10 and 12-16. A front slide 51 is slidably disposed within a longitudinally oriented channel 53 of track 25. A rear slide 55 is also slidably disposed in channel 53 of track 25 but rearward of front slide 51. Slides 51 and 55 are preferably injection molded from Delrin.RTM. 500 polyacetal plastic which can be obtained from E.I. DuPont Co. Front slide 51 has a body with a bifurcated leading end 57 and a bifurcated trailing end 59. A tail 61 of front slide 51 rearwardly and centrally extends from bifurcated end 59 and has an upper surface defined by a first deep trough 62 corresponding with a rear pivot aperture 63, a first peak 65, a second and gradual trough 66 and a rearwardly pointing second peak 67 (see FIG. 12). An integrally molded, circular-cylindrical pin 69 transversely projects from second peak 67 of tail 61. Two sets of flexible fins 71 transversely project from one side of front slide 51 while integrally molded, leaf spring-like sections 73 project from an upper surface and a lower surface of front slide 51 for providing a rattle-free fit in track 25.

Rear slide 55 is primarily bifurcated forward of a pivot aperture 81. An outboard section of rear slide 55 has a wedge-shaped leading end 83 and a pair of flexible and transversely projecting fins 85. An integrally molded, leaf spring-like section 87 is located on an upper surface of an inboard wall of rear slide 55. Section 87 and fins 85 act to snugly fit rear slide 55 in channel 53 of track 25.

A front locking shoe 91 has a pivot 93 laterally projecting inboard and outboard of a front end. A longitudinally elongated slot 95 is disposed within a main body 97 of front locking shoe 91. Slot 95 has a straight forward portion and a declining rearward portion adjacent to a somewhat squared off toe 99. Body 97 and toe 99 of front locking shoe 91 centrally rotate within an open middle section of front slide 51 whereby toe 99 is allowed to selectively project below a bottom of front slide 51. A longitudinally straight slot 101 is also molded into an inboard median body wall 103 of front slide 51 wherein slot 101 is aligned with the straight portion of slot 95 when toe 99 of front locking shoe 91 downwardly projects below front slide 51. A rear locking shoe 105 is constructed and attached to rear slide 55 in a manner similar to that with front shoe 91. However, rear slide 55 does not require a slot 101 like that employed with front slide 51. Locking shoes 91 and 105 are preferably injection molded from polyacetal plastic.

A front linkage 141 has a lower end pivotably journalled about pivot 143 of front slide 51. A longitudinally elongated bracket 145 has a leading end pivotably coupled to an upper end of front linkage 141 at pivot 147. A central link 151 has a lower end pivotably journalled to front slide 51 at pivot 63. An upper end of central link 151 is pivotably coupled to bracket 145 at pivot 153.

A curved rear link 161 has a lower, rear end pivotably journalled to rear slide 55 at pivot 81. A forward and upward end of rear link 161 is pivotably coupled to an intermediate pivot 163 of central link 151. Central and rear links 151 and 161, respectively, define a scissor linkage mechanism 165. Links 141,151 and 161, and bracket 145, are cast from Zamac 5 zinc material with a zinc (0.4-0.6 percent) iron (0.0002 inch) chromate finish. A four bar linkage arrangement is defined by bracket 145, front link 141, front slide 51 and central link 151. Raising and lowering of the four bar mechanism is essentially controlled by the scissor inducing action of rear link 161 as will be described in more detail hereinafter.

A cast aluminum alloy glass attachment bracket 201 is removably secured to bracket 145. Support 201 has a generally L-cross sectional shape, and moves concurrently with bracket 145. Support 201 is adhesively bonded to a frit coated inside peripheral surface of sunroof panel 23. A polyacetal, movable locking structure 221 is mounted between a laterally external face 223 of support 201 and L-shaped fingers 225 depending from support 201. When in a fully closed position, a pair of angled tabs 231 outwardly depending from movable locking structure 221 engage undercut surfaces 233 of respective stationary locks 235. This is shown in FIGS. 2, 5, 9 and 16. Stationary locks 235 have elongated arms 237 extending in a fore and aft longitudinal direction for engaging a channel 239 (see FIGS. 10 and 16) of each track 25. Thus, the engagement of tabs 231 with stationary locks 235 provides fore and aft sunroof panel-to-track retention on both sides of sunroof 21. The link, slides and locks are in mirrored symmetry for both tracks 25.

The operation of the present invention spoiler sunroof 21 will now be described in further detail. Referring to FIGS. 2, 5 and 8, a pin and tab end fitting 301 mounted to a distal end of drive cable 37 is located in a fully retracted position. This causes sunroof panel 23 and its operating mechanism to be disposed in a fully closed position as shown. End fitting 301 is injection molded from a glass filled nylon. In this closed position, toes 99 of locking shoes 91 and 105 downwardly project through respective apertures in a lower surface of track 25. A pin 307 of end fitting 301 acts with slot 95 and slot 101 to maintain front shoe 91 in its track engaging position while pin 69 of tail 61 interacts with the slot of rear shoe 105 to engage track 25. Furthermore, a forward edge of front slide 51 abuts against an upturned flange 303 of track while a forward edge of rear slide 55 abuts against another upturned flange 305 of track 25. The locking mechanisms 221 and 235 are also fully engaged in this closed position.

Next, the electric motor advances cable 37 and end fitting 301. This causes pin 307 of end fitting 301 to ride along slots 95 and 101 to the position shown in FIG. 11. A tab associated with end fitting 301 (see FIG. 17) will simultaneously push a downturned element 311 of movable locking structure 221 in a rearward and unlocking direction so as to disengage tabs 231 from stationary locks 235.

The electric motor subsequently causes pin 307 to move to the position illustrated in FIG. 12 for upwardly pivoting and unlocking front locking shoe 91 from the aperture of track 25. Pin 307 and front slide 51 are then linearly moved rearward to the sunroof venting position of FIGS. 3, 13 and 15, while rear slide 55 is maintained in its position. This relative slide movement causes scissor linkage 165 to vertically raise which, in turn, also pivotally raises front link 141.

FIGS. 4, 14 and 16 show the subsequent movement, wherein rearward movement of front slide causes its pin 69 to upwardly pivot rear shoe 105, engaged therewith. Thus, rear slide 55 then linearly slides rearward simultaneous with front slide 51 upon further advancing of drive cable 37. The links are maintained in their angularly raised orientation while the entire mechanism and sunroof panel 23 are moved from the vent position to the fully open position. Front slide 51 has a lower channel allowing it to freely pass over upturned flange 305 of track 25. Reversal of electric motor actuation causes a reverse order of the above described mechanism movement. Upturned flanges 303 and 305 stop forward movement of their respective slides during sunroof closure.

It is noteworthy that the use of links and linear slides minimizes motor amperage spikes due to friction and poor mechanical advantages often associated with inclined cams. The linear movement of all link pivots coincidental with the respective slides is beneficial to aftermarket "drop in" installation. Moreover, the relatively short length links provide a small packaging space while maximizing the sunroof opening area.

While the preferred embodiment sunroof mechanism has been disclosed, it should be appreciated that other variations may be employed within the spirit of the present invention. For example, the disclosed locking arrangement may be employed in a below-roof type sunroof. Furthermore, the link shapes and arrangement may also differ as long as the disclosed function is achieved. The slides may also have alternate shapes and additional links can be used. Moreover, the various pins can be integrally or separately formed from the end fitting or slides. Also, a manual crank can be used in place of the electric motor. Additionally, a metal panel can be substituted for the glass sunroof panel. 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.