US-12623521-B2 - Multi-functional sunroof assembly bracket endcap and deflector protector

US12623521B2US 12623521 B2US12623521 B2US 12623521B2US-12623521-B2

Abstract

A sunroof assembly includes a bracket removably attached to a sunroof panel and defining a cavity. The sunroof assembly also includes an endcap removably attached to the bracket that closes the cavity and maintains clearance between the sunroof panel and a deflector of the sunroof assembly by contacting the deflector as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.

Inventors

Micah S. Wedekind
Michael A. Mixon
Glover A. Kosch
Jacob C. Grimaldo

Assignees

AISIN CORPORATION

Dates

Publication Date: 20260512
Application Date: 20230913

Claims (20)

1 . A sunroof assembly, comprising: a bracket removably attached to a sunroof panel and defining a cavity; and an endcap removably attached to the bracket that closes the cavity and maintains clearance between the sunroof panel and a deflector of the sunroof assembly by contacting the deflector as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.
2 . The sunroof assembly of claim 1 , wherein the endcap defines a rounded endcap point that maintains clearance between the sunroof panel and the deflector by sliding along the deflector.
3 . The sunroof assembly of claim 1 , wherein the sunroof panel defines a sunroof panel edge lined with encapsulation material, and wherein the endcap maintains clearance between the encapsulation material and the deflector and prevents damage to the encapsulation material by sliding along the deflector during movement of the sunroof panel between the open position and the closed position.
4 . The sunroof assembly of claim 1 , wherein the deflector is spring-loaded, and wherein the endcap provides mechanical advantage to push the deflector from the raised position to the stowed position by contacting the deflector as the sunroof panel moves from the open position to the closed position, and wherein the endcap inhibits rapid movement of the deflector from the stowed position to the raised position by contacting the deflector as the sunroof panel moves from the closed position to the open position.
5 . The sunroof assembly of claim 1 , wherein the sunroof panel defines a sunroof panel edge lined with encapsulation material, wherein the encapsulation material is installed to the sunroof panel edge using a molding process, and wherein the endcap prevents the encapsulation material from entering the cavity during the molding process by closing the cavity.
6 . The sunroof assembly of claim 1 , wherein the cavity defines contours, and wherein the endcap further includes one or more legs having a shape corresponding to the contours such that when the endcap is attached to the bracket, the legs are inserted to the cavity and the endcap is secured to the bracket.
7 . The sunroof assembly of claim 1 , wherein the endcap further defines a base that removably attaches the endcap to the sunroof panel, and further comprising endcap spacers located between the base and the sunroof panel, wherein the endcap spacers prevent damage to the sunroof panel by the base by maintaining clearance between the base and the sunroof panel.
8 . The sunroof assembly of claim 1 , further comprising bracket spacers located between the bracket and the sunroof panel, wherein the bracket spacers prevent damage to the sunroof panel by the bracket by maintaining clearance between the bracket and the sunroof panel.
9 . A sunroof assembly, comprising: a sunroof panel defining a sunroof panel edge lined with encapsulation material installed to the sunroof panel edge in a molding process; a bracket removably attached to a sunroof panel and defining a cavity; and an endcap removably attached to the bracket that prevents encapsulation material from entering the cavity during the molding process by closing the cavity and that maintains clearance between a deflector of the sunroof assembly and the encapsulation material and prevents damage to the encapsulation material by contacting the deflector as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.
10 . The sunroof assembly of claim 9 , wherein the endcap defines a rounded endcap point that maintains clearance between the sunroof panel and the deflector by sliding along the deflector.
11 . The sunroof assembly of claim 9 , wherein the deflector is spring-loaded, and wherein the endcap provides mechanical advantage to push the deflector from the raised position to the stowed position by contacting the deflector as the sunroof panel moves from the open position to the closed position, and wherein the endcap inhibits rapid movement of the deflector from the stowed position to the raised position by contacting the deflector as the sunroof panel moves from the closed position to the open position.
12 . The sunroof assembly of claim 9 , wherein the cavity defines contours, and wherein the endcap further includes one or more legs having a shape corresponding to the contours such that when the endcap is attached to the bracket, the legs are inserted to the cavity and the endcap is secured to the bracket.
13 . The sunroof assembly of claim 9 , wherein the endcap further defines a base that removably attaches the endcap to the sunroof panel, and further comprising endcap spacers located between the base and the sunroof panel, wherein the endcap spacers prevent damage to the sunroof panel by the base by maintaining clearance between the base and the sunroof panel.
14 . The sunroof assembly of claim 9 , further comprising bracket spacers located between the bracket and the sunroof panel, wherein the bracket spacers prevent damage to the sunroof panel by the bracket by maintaining clearance between the bracket and the sunroof panel.
15 . A sunroof assembly, comprising: a sunroof panel defining a first corner and a second corner; a bracket removably attached to the sunroof panel that extends between the first corner and the second corner and defines a cavity having a first opening below the first corner and a second opening below the second corner; a deflector located below the sunroof panel and defining a first deflector arm located below the first corner and a second deflector arm located below the second corner; a first endcap removably attached to the bracket at the first opening; and a second endcap removably attached to the bracket at the second opening, wherein the first endcap and the second endcap maintain clearance between the sunroof panel and the deflector by respectively contacting the first deflector arm and the second deflector arm as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.
16 . The sunroof assembly of claim 15 , wherein the first endcap and the second endcap each define a rounded endcap point that maintains clearance between the sunroof panel and the deflector by sliding along the deflector.
17 . The sunroof assembly of claim 15 , wherein the sunroof panel defines a sunroof panel edge lined with encapsulation material, and wherein the first endcap and the second endcap maintain clearance between the encapsulation material and the deflector and prevent damage to the encapsulation material by respectively sliding along the first deflector arm and the second deflector arm during movement of the sunroof panel between the open position and the closed position.
18 . The sunroof assembly of claim 15 , wherein the sunroof panel defines a sunroof panel edge lined with encapsulation material, wherein the encapsulation material is installed to the sunroof panel edge using a molding process, and wherein the first endcap and the second endcap prevent the encapsulation material from entering the cavity during the molding process by respectively closing the first opening and the second opening.
19 . The sunroof assembly of claim 15 , wherein the cavity defines contours, and wherein the first endcap and the second endcap each further include one or more legs having a shape corresponding to the contours such that when the first endcap and the second endcap are attached to the bracket, the legs are inserted to the cavity and the first endcap and the second endcap are secured to the bracket.
20 . The sunroof assembly of claim 15 , wherein the first endcap and the second endcap each further define a base that removably attaches the first endcap and the second endcap to the sunroof panel, and each further comprising endcap spacers located between the base and the sunroof panel, wherein the endcap spacers prevent damage to the sunroof panel by the base by maintaining clearance between the base and the sunroof panel.

Description

TECHNICAL FIELD The subject matter described herein relates, in general, to sunroof assemblies and, more particularly, to bracket endcaps and deflector protectors for sunroof assemblies. BACKGROUND In some vehicles, sunroof assemblies include sunroof panels that open and close a sunroof opening in a roof of the vehicle. In some instances, sunroof panels are constructed from glass, allowing a passenger of the vehicle to see through the sunroof opening when the sunroof panel closes the sunroof opening. While glass provides transparency, it may flex under wind pressure as the vehicle travels forward. Accordingly, some vehicles include a bracket connected to the sunroof panel that extends laterally with respect to the vehicle and provides additional strength and rigidity to the sunroof panel. In some instances, the bracket is hollow, and the sunroof assembly additionally includes endcaps to close the bracket on either end. In some vehicles, sunroof assemblies also include a deflector for diffusing high-pressure air traveling over the vehicle when the sunroof assembly is open. In some arrangements, the deflector includes a spring-loaded deflector arm and a mesh connected to the deflector arm and one or more other components of the sunroof assembly. In some arrangements, the deflector is stored under a sunroof panel of the sunroof assembly. As the sunroof panel moves to an open position, the sunroof panel retracts and allows the spring-loaded deflector arm to rise above the vehicle and stretch the mesh such that it is taut and functional to diffuse high-pressure air. Contrariwise, as the sunroof assembly moves to a closed position, the sunroof panel pushes the spring-loaded deflector arm down such that it is in a stowed position within the sunroof assembly. In some arrangements, contact between the sunroof panel and the deflector arm may cause damage to the sunroof panel and/or the deflector arm. Moreover, in some arrangements, the respective positions of the sunroof panel and the deflector arm during closing of the sunroof assembly may provide sub-optimal mechanical advantage to push the deflector arm to the stowed position. Accordingly, some sunroof assemblies include deflector protectors, which may be attached to the sunroof panel. In vehicles that include both a bracket and a deflector, the sunroof assembly may include endcaps and deflector protectors that are both connected to the sunroof panel. In such instances, the use of both endcaps and deflector protectors requires the use of many additional fasteners for connecting the components to the sunroof panel and may increase the overall weight and cost of the sunroof assembly. SUMMARY In one embodiment, example systems relate to multifunctional bracket endcaps and deflector protectors for sunroof assemblies. In the embodiment described herein, a sunroof assembly includes a sunroof panel that opens and closes a sunroof opening of a vehicle. In some arrangements, the sunroof panel is constructed from glass, which may flex under wind pressure as the vehicle travels forward. Accordingly, in one arrangement, the sunroof assembly includes a bracket that is connected to the sunroof panel, extends laterally with respect to the vehicle, and provides additional strength and rigidity to the sunroof panel. In some instances, the bracket is bonded to the sunroof panel in a molding process in which the components of the sunroof assembly are loaded into a mold into which encapsulation material is inserted. In some instances, during the molding process, the bracket is hollow and encapsulation material may enter the bracket, which may increase the overall weight of the sunroof assembly. Accordingly, in one arrangement, the sunroof assembly also includes endcaps for closing off the hollow bracket during the molding process. For multifunctionality and to reduce the overall number of components of the sunroof assembly, in one or more arrangements, the endcaps have a geometry that enables the endcaps to additionally function as deflector protectors. Accordingly, in one approach, the endcaps include endcap points, which are rounded points configured to contact deflector arms of a deflector of the sunroof assembly. In this way, in one approach, the endcaps contact the deflector arms, which may be spring-loaded, to prevent damage to the deflector arms, the encapsulation material, and/or the sunroof panel by maintaining clearance between the sunroof panel and the deflector arms. Moreover, in one arrangement and by way of contacting the deflector arms, the endcaps also serve to provide mechanical advantage to push the deflector arms to a stowed position as the sunroof panel closes the sunroof opening and inhibit rapid movement of the deflector arms from the stowed position as the sunroof panel opens the sunroof opening. Accordingly, the arrangements described herein have the benefit of providing multifunctional bracket endcaps and deflector protectors for sunroof assemblies. As such,