GB2556350A

GB2556350A - Raising roofs for vehicles

Info

Publication number: GB2556350A
Application number: GB1705019.6A
Authority: GB
Inventors: Pendlebury Wayne
Original assignee: HILO ROOF Co Ltd
Current assignee: HILO ROOF Co Ltd
Priority date: 2016-10-06
Filing date: 2017-03-29
Publication date: 2018-05-30
Also published as: GB201705019D0; GB201617011D0

Abstract

A raising pop-top roof system 10 for a vehicle, vehicle comprising raising roof and kit of parts to convert vehicle to have said raising roof. The system comprises a raising roof panel 32 movable between a lowered position (figures 1&2) where it covers an aperture 14 in the vehicle roof 16, and a raised position (figures 3&4) such that it is spaced from the vehicle roof. The system further comprises a raising and lowering mechanism having at least one hinge 50 and at least one lift-assist 36 connected between the raising roof panel and the vehicle roof. A frame 12 may be fixed to the vehicle roof at the periphery of the aperture. The raising roof panel may comprise fibre-reinforced plastics (FRP) and may further comprise a support frame also of FRP. The hinge may comprise a swan neck or boot-type hinge. The lift assist may comprise a gas strut located in a gutter defined by the frame 12, or spring hinges. The roof system provides a minimal increase in height or profile of the vehicle roof (see figures 9&10).

Description

(54) Title of the Invention: Raising roofs for vehicles

Abstract Title: Raising pop-top roof for vehicle, vehicle comprising raising roof and kit of parts to convert vehicle to have said raising roof (57) A raising pop-top roof system 10 for a vehicle, vehicle comprising raising roof and kit of parts to convert vehicle to have said raising roof. The system comprises a raising roof panel 32 movable between a lowered position (figures 1&2) where it covers an aperture 14 in the vehicle roof 16, and a raised position (figures 3&4) such that it is spaced from the vehicle roof. The system further comprises a raising and lowering mechanism having at least one hinge 50 and at least one lift-assist 36 connected between the raising roof panel and the vehicle roof. A frame 12 may be fixed to the vehicle roof at the periphery of the aperture. The raising roof panel may comprise fibre-reinforced plastics (FRP) and may further comprise a support frame also of FRP. The hinge may comprise a swan neck or boot-type hinge. The lift assist may comprise a gas strut located in a gutter defined by the frame 12, or spring hinges. The roof system provides a minimal increase in height or profile of the vehicle roof (see figures 9&10).

FIGURE 3

1/11

FIGURE 1

FIGURE 2

2/11

FIGURE 3

FIGURE 4

3/11

FIGURE 5

FIGURE 6

4/11

ίο

FIGURE 8

5/11

FIGURE 9

FIGURE 10

6/11

FIGURE 12

7/11

FIGURE 14

8/11

100

102

9/11

FIGURE 18

10/11

100

FIGURE 21

120

11/11

Title: Raising roofs for vehicles

Description:

This invention relates to vehicle roofs, and in particular, to raising vehicle roofs.

A vehicle may be fitted with a raising roof to provide the convenience of the option of having greater internal headroom when parked; and reduced vehicle height when the vehicle is in motion.

Many types of vehicles have raising roofs, such as camper vans (in which the increased headroom is required to enable occupants to stand within the vehicle and to provided additional interior space for a bed) and service vehicles, such as mobile shops and ambulances (in which the occupants may need to stand to use equipment when the vehicle is stationary).

There are many types of raising roof that are already available on the market, and these generally comprise in inverted box that sits atop the vehicle that can be raised or lowered as required.

Known raising roofs have a certain minimum height requirement to accommodate the raising/lowering mechanism as well as the flexible web (known as the awning) that extends between the vehicle's roof and the underside of the raising roof: clearance for both of which needs to be found between the vehicle's roof and the raising roof when the raising roof is lowered. This tends to increase the overall height of the vehicle - even with the raising roof in a lowered position. The reason for this is that the raising roof needs to be structurally connected to the vehicle and this is most easily achieved by connecting its raising/lowering mechanism to the vehicle's existing roof bar mounting points. As such, the raising/lowering mechanism is generally mounted atop of the vehicle and the inverted box of the raising roof then covers the mechanism and has sidewalls that form a skirt to come down to meet, and optionally form a seal with, the vehicle's roof. Such a configuration, even if made compact, necessarily raises the height of the vehicle's roof to a certain extent, which has a number of disadvantages:

First, the overall height of the vehicle is increased, which increases its frontal area thereby adversely affecting the vehicle's aerodynamics. The increase in frontal area of the vehicle, and or the presentation of a flat surface to the oncoming wind (i.e. the flat front of the inverted box) can cause the vehicle's road handling and fuel economy to adversely affected.

Second, vehicles fitted with known raising roofs often encounter difficulties when driving in height-restricted areas, such as in multi-storey car parks. This can mean that it is difficult to use a vehicle fitted with a raising roof as an everyday vehicle.

Third, the raising roof can have an unpleasing aesthetic appearance because it detracts from the vehicle's roofline, as-designed, which can have an adverse effect on the desirability of a vehicle fitted with a raising roof and may reduce its value.

Granted UK Patent No: GB2494750B [Raising roofs for vehicles, The Hilo Roof Company

Limited, GB1212670.2, published 20 March 2013] describes an alternative type of raising/lowering roof system that addresses one or more the above problems and teaches providing a support frame that is connected inboard of the roof aperture and below the rooflineof the vehicle. This configuration enables the raising/lowering mechanism to be accommodated mostly below the roofline, which inturn enables the raising roof to lie substantially flush with the roofline of the vehicle when it is in a lowered positon.

However, even the roof described in GB2494750 suffers from drawbacks. For example, the raising/lowering mechanism comprises a scissor-lift type hinge mechanism, which is a critical, but also a bulky and expensive item. The scissor-lift type mechanism of GB2494750 hingedly connects the raising roof to the support frame, whilst constraining the roof's locus such that the rear part of the raising roof lifts as the raising roof is raised as well as the front part, albeit to a lesser degree. This increases headroom at the rear of the vehicle, which is an advantage, but the scissor-lift type mechanism may be prone to failure due to its several hingedly interconnected parts. A simpler type of hinge would therefore be desirable.

Also, in order to obtain a low-profile roofline when the raising roof is lowered, the scissor-lift type mechanism needs to be connected to the inboard and down support frame, and this requires the strength of the support frame to be substantial. Further, the scissor-lift type mechanism has a certain minimum height, even when in the folded (lowered roof) configuration, which is significantly more than that of the other components, which means the support frame needs to drop into the vehicle by a greater extent that is sometimes desirable.

A need therefore arises for an alternative and/or improved type of raising roof system for vehicles, and it is an object of the invention to provide such an alternative and/or improved raising roof system and/or to solve one or more of the above problems.

According to a first aspect of the invention there is provided a raising roof system for a vehicle comprising an aperture in the roof of its bodywork: a raising roof moveable between: a lowered position in which it closes the aperture and in which its upper surface substantially follows the original roofline of the vehicle; and a raised position in which the upper surface is displaced with respect to the original roofline of the vehicle; and a raising/lowering mechanism operatively connecting the raising roof to the vehicle, wherein the raising/lowering mechanism comprises: a hinge that hingedly connects the raising roof to the bodywork of the vehicle; and a lift-assist device pivotally connected at its upper end to an underside of the raising roof, and at its lower end, to the vehicle at a point below the original roofline of the vehicle.

Suitably, the raising roof system comprises a frame that locates in the aperture. The frame may comprise a first flange portion that extends outwardly of the frame, which first flange portion comprises an underside that rests, in use, upon a part of the vehicle's roof surrounding the aperture.

The first flange portion is suitably connected to the part of the vehicle's roof surrounding the aperture by way of any one or more of the group comprising: rivets, bolts & nuts; screws; adhesive and welding.

Suitably, the first flange portion is sealingly connected to the part of the vehicle's roof surrounding the aperture, for example, by a bead of sealant, or adhesive, interposed between the first flange portion and the part of the vehicle's roof surrounding the aperture.

Suitably, the frame comprises a second frame portion, which extends, in use, down through the aperture in the vehicle's roof to a level below the original roofline of the vehicle. The lower end of the lift-assist device may be pivotally connected to the second frame portion. Such a configuration enables the height of the lift-assist device to be accommodated at a level below the original roofline of the vehicle.

The frame may further comprise a second flange portion that extends inwardly and which provides, in certain embodiments, a support lip for supporting, in use, a bed surface. The lower end of the lift-assist device may be pivotally connected to the second flange portion. Such a configuration enables the height of the lift-assist device to be accommodated at a level below the original roofline of the vehicle.

In a preferred embodiment of the invention, the frame, where provided, is made up of one or more beams having a generally S-shaped cross-section comprising an outwardly-projecting first flange portion; an inwardly-projecting second flange portion; and a second frame portion interconnecting an inner edge of the first flange portion and an outer edge of the second flange portion.

The raising roof is moveable between a lowered position in which its upper surface substantially follows the original roofline of the vehicle and a raised position in which the upper surface is displaced with respect to the original roofline of the vehicle. The original roofline of the vehicle is the roofline of the same vehicle as it would have been without the raising roof fitted. In other words, when the raising roof of the invention is in the lowered position, the roofline of the vehicle fitted with a raising roof of the vehicle is preferably substantially of the same shape as the roofline of the same vehicle without the raising roof of the invention fitted to it. The upper surface of the raising roof substantially follows the original roofline of the vehicle; which means that the correspondence between the roofline of a vehicle fitted with a raising roof of the invention need not be exactly the same as the roofline of the same vehicle without the raising roof of the invention fitted.

In particular, there may be slight height differences, of say up to 25mm, but preferably less than about

15mm, but in any event, the overall appearance of the vehicle is substantially unaffected by the fitting of a raising roof according to the invention to it.

When the raising roof is in the raised position, its upper surface is displaced with respect to the original roofline of the vehicle. This displacement may be an inclination, i.e. a tilting of the roof; a raising of the roof; or a combination of the two.

The hinge can be of any suitable type. The hinge can be of any suitable type other than a scissor-lift type hinge.

In certain embodiments, the hinge comprises one or more leaf hinges, a first part of which may be connected to an underside of the raising roof, and a second part of which is affixed to the vehicle's bodywork. The second part of the leaf hinge may be connected to the top of the vehicle's bodywork.

Additionally or alternatively, the second part of the or each hinge may be connected to roof bar mounting points of the vehicle, or to a part of the vehicle located within its roof gutter channel.

This suitably lowers the second part of the hinge so that it is concealed from view when viewed from a position beside the vehicle.

In other embodiments, the hinge comprises one or more boot hinges, a first part of which may be connected to an underside of the raising roof, and a second part of which is affixed to an interior part of the vehicle's bodywork. The second part of the boot hinge may be connected to the underside of the vehicle's bodywork, namely its roof. An advantage of using a boot hinge over a leaf hinge is that the raising roof may be configurable to raise slightly at it pivots, thereby affording a little additional headroom within the vehicle when the raising roof is in the raised position compared with an otherwise identical raising roof having a leaf hinge. A further advantage of using a boot hinge is that the hinge can be located within the vehicle and therefore not visible from outside the vehicle when the raising roof is in the lowered position.

A fascia may be provided to conceal the second part of the hinge or hinges, and/or to blend the profile of the raising roof into the vehicle's bodywork when the raising roof is in the lowered position.

Preferably, the hinge is connected to a reinforced part of the vehicle's bodywork, for example, a part of the roof that is supported by a cross-brace, cross-beam or longitudinal beam.

In a preferred embodiment of the invention, the raising roof has a downwardly projecting peripheral lip along one or more edges thereof, but preferably along its side edges, which peripheral lips terminate at a point lying within a gutter portion of the vehicle's roof. This enables the edges of the raising roof to be concealed within the gutter, and/or for them to have an unfinished edge which is not visible when the raising roof is in the lowered position.

In certain embodiments of the invention, the edges of the raising roof, or its peripheral lips, where provided, comprise edging strips, which may be elastomeric edging strips, which may form a seal between the raising roof the vehicle's bodywork. Preferably, a weather-tight seal is provided between the periphery of the raising roof and the frame, such as a compressible foam or rubber strip that seats against the frame to keep rainwater and wind out of the interior of the vehicle.

Suitably the roof is manufactured from lightweight materials, such as glass fibre reinforced plastic (GRP) or carbon fibre reinforced plastic (CFRP). The use of these materials, or any materials of the like, is beneficial for rigidity, ease of manufacture, resistance to weathering and to reduce its weight, which may improve the vehicle's fuel economy to which it is fitted. Also, GRP and CFRP parts can be easily colour-matched to the vehicle's bodywork.

Preferably, the raising roof is manufactured from a GRP moulding having an outer and an inner skin with a honeycomb or foam material interposed between the skins to provide thermal and/or acoustic insulation, and to increase the rigidity of the raising roof and hence its resistance to deformation under wind loading.

Additionally, the raising roof may comprise a flexible web or awning forming, when in the raised position, a wall around the space between the roof and the frame. The awning is suitably waterproof and/or weather tight to keep out the elements. The shape and configuration of the awning is suitably such that when the roof is at its fully-open position, the awning becomes taut.

The awning may comprise one or more window/door apertures, which in preferred embodiments, comprise any one or more of the group comprising: an openable/closeable fly screen;

an openable/closeable transparent sheet (or window); and an openable/closeable opaque sheet.

It will be appreciated that the invention could be used, for example, in a camper van type vehicle. Additionally or alternatively, the invention could be used to provide a hybrid sport lid cum canopy roof for the bed of a truck-type vehicle. Additionally or alternatively, the invention could be used in other types of vehicles, such as vans, or estate (station wagon)-type ambulances where, on occasion, standing headroom within the vehicle may be required.

The raising roof may be lockable in the lowered position by one or more catches or locking members. In a preferred embodiment of the invention, a lock-down member is provided at each corner of the roof, and may comprise a removable hand-locking bolt that can be concealed, for example, behind a windscreen sun visor, or behind a flap in the headlining of the vehicle. Preferably, at least one of the locking members is secured by a key- or remotely-operated lock.

A second aspect of the invention provides a vehicle fitted with a raising roof system as described herein.

A third aspect of the invention provides a kit of parts for converting a vehicle to a vehicle with a raising roof as described herein.

Embodiments of the invention shall now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a schematic longitudinal cross-sectional view of an embodiment of a raising roof system in accordance with the invention in the lowered position;

Figure 2 is a schematic transverse sectional view of the raising roof system of Figure 1;

Figure 3 is a schematic longitudinal cross-sectional view of the raising roof system of Figure 1 in the raised position;

Figure 4 is a schematic transverse sectional view of the raising roof system of Figure 3;

Figure 5 is a schematic longitudinal cross-sectional view of another embodiment of a raising roof system in accordance with the invention in the lowered position;

Figure 6 is a schematic transverse sectional view of the raising roof system of Figure 5;

Figure 7 is a schematic longitudinal cross-sectional view of the raising roof system of Figure 5 in the raised position;

Figure 8 is a schematic transverse sectional view of the raising roof system of Figure 7;

Figure 5 is a cross-sectional side-view of the raising roof system in accordance with a second embodiment of the invention, in the lowered position;

Figure 6 is a cross-sectional rear-view of the raising roof system of Figure 5;

Figure 7 is a cross-sectional side-view of the raising roof in accordance with the second embodiment of the invention, in an elevated position;

Figure 8 is a cross-sectional rear-view of the raising roof system of Figure 7;

Figure 9 is a perspective view of the raising roof system in the lowered position;

Figure 10 is a perspective view of the raising roof system of Figures 1 to 4 with the raising roof in the elevated position;

Figure 11 is a perspective view of the raising roof system of Figures 5 to 9 with the raising roof in the elevated position;

Figure 12 is a perspective view of an alternative embodiment of a raising roof system according to the invention with the raising roof in the elevated position;

Figure 13 is a schematic longitudinal cross-sectional view of the raising roof in accordance with another embodiment of the invention, in the raised position;

Figure 14 is a close-up view of Figure 13;

Figure 15 is a side-rear perspective view of an embodiment of a roof as shown in Figures 1 to of the drawings;

Figure 16 is an exploded view of the roof of Figure 15;

Figure 17 is a front perspective view of the roof of Figure 15;

Figure 18 is an exploded view of the roof for Figure 17;

Figures 19 to 21 are a sequence showing the installation of the raising roof of Figures 15 to 18 onto a vehicle; and

Figure 22 is a partially transparent view of the raising roof of Figure 17.

Referring to Figures 1, 3, 5 and 7 of the drawings, a raising roof system 10 in accordance with the invention comprises a main support frame 12 comprising a set of four structural beams that sit in a correspondingly shaped aperture 14 in a roof 16 of a vehicle (not shown for clarity). Each of the support beams 12 comprises a generally flat upper flange 18, which seats in a rebate 20 surrounding the aperture 14 in the vehicle roof 16. Depending substantially vertically down from the upper flange is a vertical beam portion 22, which extends down through the opening 14 in the vehicle roof 16 and which terminates in an inwardly-directed lower flange portion 24 that lies at a level slightly below the level of the roof 16 of the vehicle. The lower flange portion 24 can be used to support a bed (shown schematically as box 26) and in the illustrated embodiments, provides a convenient belowthe-roofline fixing point for a gas strut 36, which will be described in greater detail later.

A raising roof 32, which is slightly larger than the aperture 14, is mounted over the aperture and closes it when in the lowered position, as shown in Figures 1 and 5. As can be seen in Figures and 6 of the drawings, the raising roof 32 has peripheral edges 34, that drop down into a longitudinal rain gutter channel 60 of the vehicle roof 16, when the raising roof 32 is lowered. This configuration serves to shed rainwater into the gutter channel 60, and also conceals the edges 34 from view when the raising roof 32 is lowered. In certain embodiments, the edges 34 contact the roof 16 when the raising roof is lowered, but this is not essential.

A gas strut 36 is interposed between the underside of the raising roof 32 and the lower flange portion 24. The gas strut 36 supports the weight of the raising roof 32 when it is raised. The gas strut is pivotally connected 38 at its lower end to the lower flange portion 24, and at its upper end 40 to the underside of the raising roof 32. It can be seen from the drawings that the lower end of the gas strut 36 is connected at a pint below normal level of the roof 16 of the vehicle. In the lowered position, therefore, as is shown in Figures 1 and 5 of the drawings, the gas strut is accommodated mostly below the roofline of the vehicle.

In a first embodiment of the invention, shown in Figures 1 to 4, the raising roof 10 comprises one or more leaf hinges 50. The leaf hinges 50 comprises two interconnected portions configured to move relative to one another. A first portion 52 of each leaf hinge 50 is affixed to the underside of the raising roof 32 and a second portion 54 of each leaf hinge is affixed to the beam 56 of the vehicle.

Connection between the second portion 56 of the hinge 50 and the beam 56 of the vehicle is suitably achieved by way of a nut and bolt arrangement 58, but it is envisaged that alternate means of interconnection may be employed within the scope of the invention.

In the lowered position, as seen in Figures 1 and 2, the portions of the leaf hinge 50 are both at substantially 180 degrees to one another, and the raising roof 32 lies in a substantially horizontal plane. The raising roof 32 can be seen to sit at a slightly higher level than the existing roofline 16, but this height difference is minimal and the profile of the raising roof 32 is in any event designed to substantially follow the shape of the roof 16.

Because the raising roof 32 sits on top of the roof, there is a possibility that when the vehicle is driven at speed, that wind may tend to try to lift the front edge of the roof. A spoiler strip 63 is therefore fitted to the top edge of the vehicle's windshield, which deflects the wind over the top of the front edge of the raising roof 32, thereby reducing this potential issue. At the rear of the raising roof, a moulded fascia plate 62 is provided, which blends the profile of the raising roof back into that of the vehicle's roofline 16, thereby concealing the leaf hinges 50 and providing a pleasing appearance.

In use, the raising roof 32 is elevated by a user (facilitated by the gas strut 36) by pushing the roof 32 upwards from below. The leaf hinges 50 cause the rear edge of the raising roof 32 to pivot neatly about the shut line 71 between the raising roof's rear edge and the fascia plate 62. This configuration ensures a near appearance when the raising roof 32 is either lowered or raised, as can be seen in Figures 10 and 11 of the drawings. The awning 53 is shown in Figure 3.

In the raised position, as shown in Figures 3, 4 and 10, the raising roof 32 is inclined by about

40-45 degrees, but is will be appreciated that the pitch of the roof is determined by the extended length of the gas struts 36. Tilting the raising roof 32 in this way provides an additional amount of headroom within in the vehicle, particularly towards the front end where the raising roof 32 is at its highest point.

In a second embodiment of the invention, as is shown in Figures 5 to 8 and 11 of the drawings, instead of having leaf hinges 50, the raising roof system 10 comprises one or more boot hinges 70.

Each booth hinge 70 comprises an arcuate linkage that is rigidly affixed at its distal end to the raising roof (preferably the underside of the raising roof); and at its proximal end, to the vehicle's bodywork (preferably the underside of the vehicle's bodywork) via a pivoting connection.

The boot hinge 70 may, in certain embodiments, be spring-loaded to provide partial or complete support for the weight of the roof, thereby reducing or removing the support requirement of the gas struts 36, but this is not essential. Referring to Figures 13 and 14 of the drawings, a spring can be seen to be located at the pivoting connection of the boot hinge 70. When the raising roof

32 is in the lowered position, the spring 80 will be compressed, such that upon elevation of the raising roof the spring 80 will extend, exerting an opposing force N on the arcuate linkage of the boot hinge and subsequently on the raising roof 32, thus facilitating the upward movement of the raising roof 32.

One end of each boot hinges 70 is connected to a structural part of the vehicle's roof 60, in this case, the underside of the lateral beam 56 of the vehicle previously described. Each boot hinge

70 comprises an arcuate limb portion 74 whose distal end connects to the underside of the raising roof 32.

In the lowered position, as shown in Figures 5 and 6 of the drawings, the boot hinge 70 can be seen to located entirely below the roofline 16 of the vehicle and is preferably concealed internally of the vehicle within a pillar. As previously described, in the lowered position the raising roof 32 substantially follows the shape of the roof 16 of the vehicle.

In use, the raising roof 32 can elevated as previously described by pushing upwards from below the raising roof 32. This time, however, the boot hinges 70 cause the rear edge of the raising roof 32 to follow an arcuate path, which raises the rear edge of the raising roof 32 slightly when it is in the raised position.

In this embodiment, as shown in Figures 7,8 and 11 of the drawings, the continuity of roofline between the rear edge of the raising roof 32 and the fascia plate 62 is broken somewhat, but this has the advantage of increasing the headroom 75 at the rear of the vehicle compared with the headroom of the leaf hinge embodiment previously described. The relative difference 79 in headroom can be configured by the design and placement of the boot hinges 70, as will be readily apparent to the skilled reader.

The use of boot hinges 70, as opposed to leaf hinges 50, has the advantage of raising both the front and rear edges of the raising roof 32 when it is in the raised position, which increased the interior volume of the vehicle, especially at the foot end of a bed 26 supported by the beams 12, where provided.

Figure 12 of the drawings shows an alternative embodiment of the leaf hinge version of the invention, which the leaf hinges 50 are connected to the rain gutter 60 of the vehicle's roof. The leaf hinges 50 would be concealed below the raising roof 32, of course, but in the drawing they have been superimposed so that the reader can see where they are located. In this embodiment, the shut line between the raising roof 32 and the vehicle's bodywork can be moved to the rear of the vehicle, thereby obviating the need for a fascia plate 62. This configuration also closer resembles the original appearance of the vehicle when the raising roof 32 has been lowered.

A preferred embodiment of the invention is shown in Figures 15 to 23 of the drawings, in which a hinged raising roof system 100 is fitted to the top of a vehicle 102.

The raising roof system 100 comprises a GRP-moulded raising roof portion 104, which is moulded/formed so as to have a shape that is broadly similar, albeit slightly higher (for reasons that shall become apparent from the description below), to the original shape of the vehicle's 102 roof.

The GRP-moulded raising roof 104 has stiffening ribs 106 moulded into its upper surface and a downturned lip 108 on either side, which runs along its side edges. The downturned lip 108 is tapered slightly so that it is deeper at the rear of the vehicle 102 than at the front, as can be seen more clearly in Figure 16 of the drawings.

The GRP-moulded raising roof 104 is secured, for example by bonding, laminating, etc., onto an underlying support frame 110, which is formed by lengths of welded-together, square-section steel tubing. The support frame 110 has a generally rectangular front portion 112 and a pair of spaced apart limb portions 114 that extend rearwardly from the front portion 112. The limb portions 114 are cranked slightly, relative to the front portion 112, so that the support frame 110 conforms better to the shape of the vehicle 102 beneath it.

The rear ends of the limb portions 114 are fitted with rearwardly-projecting leaf hinges 116 that are bolted, screwed, riveted, bonded or otherwise affixed to the top surface 118 of the vehicle's original roof.

A fairing panel 120 is also fitted atop the vehicle's existing roof 118, behind the GRP-moulded raising roof portion 104/leaf hinges 116 - so as to form a neat installation, as can be seen in Figure 16 of the drawings. The shut line 117 between the rear edge of the GRP-moulded raising roof portion

104 and the front edge of the fairing panel 120 is ideally minimised, for appearances' sake, as well as to reduce wind flowing under the fairing panel 120 as the vehicle 102 is driven forwards at speed. In certain embodiments, the very rear edge of the GRP-moulded raising roof portion 104 may comprise a slightly upturned trailing edge - even by only a few millimetres - to deflect wind up and over the front edge of the fairing panel when the vehicle 102 is driven forwards, but this is not essential.

Notably, as can be seen from Figures 15 and 17 of the drawings in particular, the downturned lip part 108 of the GRP-moulded raising roof 104, or at least is lowermost edges; as well as the side edges of the fairing panel 120, project downwardly into a gutter 122 that runs parallel to the side edges of the vehicle's roof 118. This configuration beneficially conceals the lower edges of the GRP14 moulded raising roof 104, and the fairing panel 120, in the gutter, or at least slightly below the roofline of the original roof 118.

It will be appreciated that because the preferred embodiment of the raising roof system 100 has a support frame 110 that is located on top of the vehicle's roof 118, that the overall height of the

GRP-moulded raising roof 104 is, in practice, slightly higher than the original vehicle's roofline.

However, by dropping the side edges 108 of the GRP-moulded raising roof 104, as well as the side edges of the fairing panel 120 into the gutter, this gives rise to the illusion, or appearance, of the GRPmoulded raising roof 104 having a much lower profile that it, in fact, has. In addition, this configuration avoids the appearance of having something sitting on top of the roof, as is the case with known raising roof systems. Indeed, when the vehicle is viewed by a person standing on the ground adjacent to the vehicle 102, the presence of the raising roof system 100 is not immediately apparent because it has an integrated look, unlike most existing/known raising roof systems.

Turning now to Figure 18 of the drawings, the raising roof system 100 is shown as an exploded view so that its various components can be better seen. As previously described, the raising roof system 100 has a GRP-moulded raising roof panel 104, which is laminated or otherwise bonded onto an underlying support frame 110. A canvas 124 is suspended from the underside of the GRP-moulded panel 104 and/or the support frame 110 by its upper edge 126. The canvas' lower edge 128 can be connected to and/or around the periphery of an aperture 130 cut into the roof 118 of the vehicle 102.

The leaf hinges 116 are screwed, bolted, riveted etc. through the vehicle's existing roof 118, via pre-drilled or self-tapped bolt holes 132. In a most preferred embodiment of the invention, the locations of the bolt holes 132 are chosen/designed to align with an underlying support beam (not visible) of the vehicle's existing roof 118. By connecting the raising roof system 100 to the vehicle's roof 118 via these already-strengthened points, the durability, stiffness, and strength of the raising roof system 100 can be greatly improved.

A bead of sealant and/or adhesive may be interposed between the underside of the leaf hinges 116 and the surface of the vehicle's roof 118, which may increase the strength of the connection, as well as thread-locking the screws or bolts, and/or proofing the bolt holes 132 against water and/or dirt ingress.

Also shown in Figure 18, is a set of gas struts 134, which are bolted 136, via pivot connections, at their lower ends, to points located within the gutter 122 of the vehicle's roof 118; and at their upper ends to connections points in the sides of the support frame 110 of the raising roof system 100. This configuration means that when the raising roof system 100 is in the lowered position, the gas struts

134 are accommodated within the gutter 112, i.e. between the gutter 112 and the underside of the downturned lips 108 of the GRP-moulded raising roof 104/the sides of the support frame 110.

The fairing panel 120 can be bonded, riveted, or otherwise secured to the top of the vehicle's roof 118 behind the GRP-moulded raising roof panel 104 by any suitable means. It will be appreciated that the overall appearance of the vehicle with the raising roof system 100 fitted is generally better where the side edges 121 of the fairing panel 120 also drop into the gutter 122 of the vehicle 102.

Installation of the raising roof system 100 shown in Figures 15 to 18, is shown schematically by the sequence of Figures 19 to 22.

To install the raising roof system 100, a rectangular-shaped aperture 130 is first cut into the roof 118 of the vehicle 102. Then, the raising roof 100 is placed onto the roof 118 and fitted as follows:

In Figure 19, it can be seen that the raising roof system 100 comprises a main sub-assembly

150, which comprises the GRP-moulded raising roof panel 104, the underlying support frame 110 (not visible in Figure 19), the leaf hinges 116, and the canvas 124. To begin the installation, the front edge

152 of the main sub-assembly 150 is placed into a small gap formed by a channel located behind the top edge of the vehicle's windscreen 154.

Typically, the roof 118 of a vehicle 102 has a small channel that runs laterally across the width of the vehicle immediately behind the top edge of the windscreen 154. The very front edge 152 of the

GRP-moulded raising roof panel 104, in embodiments of the invention, is tapered to an edge, which can be accommodated within this channel. The sub-assembly 150 can be lowered 160 onto the top of the vehicle 102 so that its front edge 152 engages the rear of the upper edge of the windscreen

154. This roughly aligns the sub-assembly 150 with the roof 118. Then, the rear of the sub-assembly

150 can be lowered 170 down until the sub-assembly 150 rests on top of the vehicle's roof 118, as shown in Figure 19.

Then, as shown in Figure 21 of the drawings, the sub assembly can be maneuvered 175, with its front edge 152 still engaging the back of the upper edge of the windscreen 154 - so that the gap

178 between the side edges of the GRP panel 104 and the gutter 122 is even. Once the sub-assembly

150 has been accurately positioned to the satisfaction of the installer, i.e. up against the back edge of the windscreen 154; and evenly-spaced relative to the gutters 122 of the vehicle 102, bolts, rivets, screws or other fixing means can be used to affix the leaf hinges to the top surface 118 of the vehicle's existing roof. This mechanically connects the sub-assembly 150 to the vehicle 102 and the subassembly is now able to pivot about the leaf hinges 106, as shown in Figure 22.

Referring to Figure 22 now, the installation proceeds by raising 182 the front edge 152 of the sub-assembly 150, which, of course, pivots about the leaf hinges 116. The sub-assembly 150 can be temporarily propped up in position, in a raised position, so that the gas struts 134 can now be screwed, bolted or otherwise fixed in position. As previously mentioned, the lower ends of the gas struts 134 are bolted 136 into the gutter 122 of the vehicle's roof; whereas their upper ends 138 are bolted sideways into the support frame 110 ofthe sub-assembly 150. This is done on both sides of the vehicle

102 and the temporary prop can now be removed because the gas struts 134 will now support the weight of the sub-assembly 150 in the raised position, as shown in Figure 22 of the drawings.

Next, the lower edge 128 of the canvas 124 can be fitted to the periphery of the aperture 130 in the vehicle's roof 118 and a seal formed by any suitable means, such as by clamping the lower edge

128 ofthe canvas 124 under a clamping strip, etc.

Finally, the fairing panel 120 can be dropped into position and affixed to the vehicle's roof 118 using any suitable means, such as an adhesive, rivets, bolts, etc.

Figure 23 of the drawings shows a transparent version of Figure 17, which for the purposes of illustration only, shows how the gas struts 134 are accommodated in the gutter 122 of the vehicle's roof 118 between the downturned edges 108 of the GRP-moulded panel 104 and the outer sides of the support frame 110. The front edge of the fairing panel 120 is a close fit against the rear edge of the GRP-moulding 104 - to form a neat overall installation - and it can be seen also that the leaf hinges

116 are concealed underneath the rear fairing panel 120 once the installation has been completed.

Furthermore, the front edge 152 of the GRP-panel 104 is neatly concealed behind the rear edge of the top of the windscreen 154 and this not only creates a very neat appearance, but it also enables the windscreen 154 to act as a fairing or spoiler, thereby preventing wind from getting under the front edge 152 of the GRP-panel when the vehicle 102 is in motion, and thereby lifting. By positioning the front edge 152 of the GRP-panel 104 behind the back of the top edge of the windscreen

154, this avoids the need for an additional fairing strip or spoiler to be fitted to the top edge of the windscreen 154, as is customarily the case.

The invention is not restricted to the details of the foregoing embodiments, which are merely exemplary of the invention. In particular: any shapes, dimensions or materials (whether expressly stated or implied) are merely illustrative of the invention without necessarily being restrictive of the scope of the invention, which scope is determined by the appended claims.

Claims

Claims:

1. A raising roof system for a vehicle having an aperture in a roof of its bodywork, the raising roof system comprising:

a raising roof moveable between: a lowered position in which it covers the aperture; and a raised position in which it is displaced with respect to the original roofline of the vehicle; and a raising/lowering mechanism operatively connecting the raising roof to the vehicle, the raising/lowering mechanism comprising:

a hinge hingedly connecting the raising roof to the bodywork of the vehicle; and a lift-assist device pivotally connected at its upper end to an underside of the raising roof, and at its lower end, to the bodywork of the vehicle.

2. The raising roof system of claim 1, wherein the raising roof comprises a raising roof panel and a support frame therefor.

3. The raising roof system of claim 2, wherein the support frame is bonded to an underside of the raising roof panel.

4. The raising roof system of claim 3, wherein raising roof panel is manufactured from fibrereinforced plastics, and wherein the support frame is laminated to the underside ofthe raising roof panel by fibre-reinforced plastics.

5. The raising roof system of any preceding claim, wherein the lift-assist device comprises a gas strut.

6. The raising roof system of claim 5, wherein the roof of the vehicle comprises a gutter, and wherein a lower end of the gas strut is pivotally connected to the bodywork via a pivotal connection connected to a point within the gutter.

7. The raising roof system of any preceding claim, wherein the raising roof comprises a raising roof panel, wherein the roof of the vehicle comprises a gutter, and wherein the raising roof panel comprises a downturned lip running along its side edge substantially parallel to the gutter, the downturned lip comprising a lower edge, which at least partially protrudes into the gutter when the raising roof is in the lowered position.

8. The raising roof system of claim 7 when dependent on claim 6, wherein when the raising roof is in the lowered position, the gas strut is accommodated in a space between the gutter and an underside of the downturned lip.

9. The raising roof system of any preceding claim, wherein the hinge comprises a leaf hinge.

10. The raising roof system of claim 9, when dependent on claim 2, wherein a first leaf of the leaf hinge is connected to the support frame, and wherein a second leaf of the leaf hinge is connected to the top of the bodywork forming the vehicle's roof.

11. The raising roof system of claim 10, wherein the location of the second leaf coincides with a strengthening beam formed in an underside of the bodywork forming the vehicle's roof.

12. The raising roof system of claim 9, 10 or 11, wherein the first leaf is welded to the support frame.

13. The raising roof system of claims 9 to 12, wherein the second leaf is screwed, bolted or riveted to the top of the bodywork forming the vehicle's roof support frame.

14. The raising roof system of claim 13, further comprising a bead of sealant and/or adhesive interposed between the second leaf and the top of the bodywork forming the vehicle's roof.

15. The raising roof system of any preceding claim, wherein the raising roof is manufactured from a GRP moulding having an outer and an inner skin with a honeycomb or foam material interposed between the skins.

16. The raising roof system of any preceding claim, wherein the raising roof comprises a tapered or chamfered front edge configured to lie immediately behind and below a rear surface of a top edge of a windscreen of the vehicle when in the lowered position.

17. The raising roof system of any preceding claim, further comprising a fairing panel located immediately behind the raising roof.

18. The raising roof system of claim 17, wherein the fairing panel comprises downturned side lips whose lower edges project at least partially into a gutter formed in a roof of the vehicle.

19. The raising roof system of any preceding claim, wherein the hinge comprises a single hinge extending substantially across the entire width of a rear edge of the raising roof.

20. The raising roof system of any preceding claim, comprising a plurality of hinges disposed at intervals across the width of a rear edge of the raising roof.

21. The raising roof system of any preceding claim, wherein the hinge comprises a boot hinge.

22. The raising roof system of claim 21, wherein the boot hinge comprises an arcuate linkage that is rigidly affixed at its distal end to the raising roof; and at its proximal end, to the vehicle's bodywork via a pivoting connection.

23. The raising roof system of claim 22, wherein the distal end of the boot hinge is connected to an underside of the raising roof.

24. The raising roof system of claim 22 or claim 23, wherein the proximal end of the boot hinge is connected to an underside of the vehicle's bodywork.

25. The raising roof system of any preceding claim, wherein the lift-assist device comprises a spring.

26. The raising roof system of claim 25, wherein the spring forms part of the hinge, and is configured to urge the raising roof towards the raised position.

2J. The raising roof system of any preceding claim, wherein a lower end of the lift-assist device is connected to the vehicle at a point below the vehicle's roof line.

28. The raising roof system of any preceding claim, further comprising a frame that locates in the aperture, the frame comprising a first flange portion that extends outwardly of the frame, which first flange portion comprises an underside that rests, in use, upon a partof the vehicle's roof surrounding the aperture.

29. The raising roof system of claim 28, wherein the first flange portion is connected to a part of the vehicle's roof surrounding the aperture by way of any one or more of the group comprising: rivets, bolts & nuts; screws; adhesive and welding.

30. The raising roof system of claim 28 or claim 29, wherein the first flange portion is sealingly connected to a part of the vehicle's roof surrounding the aperture by any one or more of the group comprising: a bead of sealant interposed between the first flange portion and the part of the vehicle's roof surrounding the aperture; and a bead of adhesive interposed between the first flange portion and the part of the vehicle's roof surrounding the aperture.

31. The raising roof system of claim 28, 29 or claim 30, wherein the frame comprises one or more beams each comprising an outwardly-projecting first flange portion; an inwardly-projecting second flange portion; and a second frame portion interconnecting an inner edge of the first flange portion and an outer edge of the second flange portion.

32. The raising roof system of claim 31, wherein the inwardly-projecting flange portion forms a supporting lip suitable for supporting, in use, a bed support surface within the interior of the vehicle.

33. The raising roof system of any of claims 25 to 32, wherein the lower end of the lift-assist device is connected to the second frame portion.

34. The raising roof system of any of claims 28 to 33, wherein the lower end of the lift-assist device is connected to the second flange portion.

35. The raising roof system of any preceding claim, wherein, when the raising roof is in a lowered position, its upper profile follows the shape of the existing vehicle roof.

36. The raising roof system of any preceding claim, wherein a periphery of the raising roof comprises a seal.

37. The raising roof system of any preceding claim, wherein the raising roof comprises a downwardly projecting lip portion having an edge that locates in a rain gutter channel of the vehicle's roof when the raising roof is in the lowered position.

38. The raising roof system of any preceding claim, further comprising an awning extending between a periphery of the aperture in the vehicle's roof and the underside of the raising roof.

39. The raising roof system of claim 38, wherein the awning comprises any one or more of the group comprising: a zip-closeable window panel; a zip-closeable fly screen; and a zip-closeable curtain.

40. A vehicle fitted with a raising roof system according to any preceding claim.

41. A kit of parts for converting a vehicle to a vehicle with a raising roof according to any preceding claim.

Intellectual

Property

Office

Application No: GB1705019.6 Examiner: Mr Matthew Hanson