11111111
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`liii
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`111111
`
`11111
`
`11111
`
`11111
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`11111
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`11111
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`III
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`11111111
`
`111111
`
`US007077462B
`
`12 United States Patent
`De Gailard
`
`10 Patent No
`45 Date of Patent
`
`US 7077462
`Jul 18 2006
`
`54 MODULAR AUTOMOBILE ROOF
`
`75 Inventor
`
`Franeois De Gaillard Mouilleron en
`Pareds FR
`
`73 Assignee Webasto Vehicle Systems
`International GmhH Stockdorf DE
`
`Notice
`
`Subject
`
`to any disclaimer
`is extended or adjusted
`patent
`U.S.C 154b by
`days
`
`the term of this
`
`under 35
`
`10/297294
`
`5.540478
`
`5.599059
`
`7/19% SchOeh
`Sham
`
`2/1997
`
`5/2000
`
`Ewing et al
`
`1/2002
`
`Seifert
`
`6.056352
`6.340204 St
`6.502895 Bt
`6.682132 Bt
`FOREIGN PATENT DOCUMENTS
`
`1/2003
`
`1/2004
`
`Taylor
`Hahn
`
`524303
`
`533581
`
`133974
`
`3429880
`
`3725807
`
`3/1956
`
`5/1958
`
`9/1929
`
`2/t986
`
`2/t988
`
`280/748
`
`296/2t4
`
`296/2 16.07
`
`296/178
`
`296/215
`
`296/216.02
`
`296/216.02
`
`296/216.02
`
`296/197
`
`296/210
`
`21 AppI No
`
`22 PCT Filed
`86 PCT No
`371 cl
`
`Date
`
`Jun
`
`2000
`
`PCT/EPO0/05125
`
`Dec
`
`2002
`
`87 PCT Pub No WO01/94141
`
`PCT Pub Date Dcc 13 2001
`
`51 tnt Cl
`B601 7/00
`52 U.S Cl
`
`2006.01
`
`296/216.01
`
`296/193.04
`
`296/216.04
`296/210
`
`58 Field of Classification Search
`296/216.01
`296/197
`210 193.03 193.04 102 211 215
`178 216.04
`296/216.02
`See application file for complete search history
`
`56
`
`References Cited
`
`U.S PATENT DOCUMENTS
`
`BE
`BE
`CH
`DE
`DE
`DE
`DE
`FR
`GB
`GB
`GB
`tr
`WO
`
`4024837
`296 01 330 Ui
`1329277
`
`386150
`
`405430
`
`184 404
`
`484533
`WO 00/29234
`
`2/t992
`
`6/1996
`
`4/1963
`
`1/1931
`
`2/1934
`
`6/t987
`
`9/t953
`
`5/2000
`
`296/2 tO
`
`296/210
`
`296/216.02
`
`296/178
`
`296/t78
`
`cited by examiner
`
`PrimaryExaminer
`74 Attorney Agent or Firm David
`
`Dennis
`
`Pedder
`
`Safran
`
`57
`
`ABSTRACT
`
`bodyshell
`
`comprising
`
`modular roof of an automobile
`roof structure
`which has
`front and rear transverse
`member
`right and left side member
`or
`and
`or
`The modular roof has at least
`two modular roof elements
`14 15 which are fixed directly to the roof structure
`The
`14 15 which extend over the
`modular roof elements
`entire breadth of the roof structure are preferably fixed
`which
`releasably fixed to the side members
`especially
`lie opposite each other
`
`Dt55.6t4
`2921814
`
`10/1949
`Klein et al
`1/1960 Mede
`
`296/2t0
`
`296/2t5
`
`15 Claims
`
`Drawing Sheets
`
`UUSI LLC
`Exhibit 2017
`
`WEBASTO ROOF
`SYSTEMS INC
`Petitioner
`
`UUSI LLC
`Patent Owner
`
`Case
`
`PR2014-00649
`Patent 7548037
`
`1/10
`
`WEBASTO EX. 1035
`WEBASTO ROOF SYSTEMS, INC. v. UUSI, LLC
`IPR2014-00650
`Page 1
`
`

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`Jul 18 2006
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`FIG
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`23
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`24
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`25
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`22
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`Jul 18 2006
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`FIG
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`29
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`20
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`FIG
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`17
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`14
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`20
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`FJG.7
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`321817
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`Jul 18 2006
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`Jul 18 2006
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`US 7077462 BI
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`member can be closed by
`least one other roof module
`element
`the roof module elements can be covers
`In general
`roof parts such
`transparent covers glass covers or functional
`as openable roof parts and especially sliding roof units
`Feasibly the roof structure is made of sheet metal but
`also other materials such as high-strength
`plastics can be
`used
`
`roof module elements can be made fra
`The individual
`sliding roof
`meless or they can have
`frame especially
`as
`roof module element or
`sliding roof unit can have
`15 unit
`frame with
`front and
`back cross frame element and
`right and
`left side frame element and can hold
`which is movably
`supported on the frame each of the side
`frame elements comprising means for attaching this side
`side member and each of the
`is frame element
`to the
`
`cover
`
`MODULAR AUTOMOBILE ROOF
`
`BACKGROUND OF THE INVENTION
`
`Field of the Invention
`
`Thit
`
`invention
`
`relates to
`
`modular
`
`roof
`
`for
`
`motor
`
`hack
`
`fmnt and
`roof shell structure with
`vehicle having
`left side member
`cmss member and
`right and
`Description of Related Art
`sliding mof on the top part of the roof of
`Mounting
`conventional motor vehicle which
`has
`roof structure
`especially made of sheet metal
`is known Conventionally
`an
`opening is made in the
`top part of the roof and then the
`sliding mof unit is installed However
`even if high quality
`in this way producing
`an opening
`is possible
`installation
`represents an additional working
`process in addition to the
`conventional
`pmcesses of shaping the top part of the roof
`Likewise the equipment necessary for pmducing this open
`investment compared to that which is
`ing requires additional
`conventional motor vehicle without
`necessary for
`roof
`Published German Patent Application DE 35 45 871 Al
`and counterpart published UK Patent Application
`184 404
`vehicle roof which has an installation unit
`disclose
`the form of mof cap which can be placed later on at
`least
`the side roof members of
`roof structure and can be fixed
`thereto
`ventilation means such
`ready-mounted
`spoiler roof is integrated
`example sliding roof or
`roof cap However
`roof caps which as an instal
`different
`lation unit always have the same size which is matched to
`the location of the roof members so that it can be attached
`to she roof
`iueusbers
`U.S Pat No 5540478 discloses
`roof structure for
`motor vehicle in which die vehicle manufacture provides
`roof shell with dimensionnlly defined master mounting
`points to which
`modular roof insert which is completely
`can be mounted
`aupplicr with
`sunroof
`premounted by thc
`In this way regardless of
`the roof superstructure of
`the
`roof parts to be attached thcreto assembly always
`differcnt
`sakes place at the same master mounting points at the vehicle
`manufacturer
`
`sliding
`
`in
`
`as for
`
`into the
`
`SUMMARY OF THE INVENTION
`
`least
`
`The primary object of this invention is to devise
`genenc
`modular
`roof which enables more vanable configuration of
`and motor
`she vehicle roof with simplified producsion
`vehicle with such
`modular
`roof
`is achieved in
`roof by the
`This object
`general modular
`modular
`roof having at
`two roof module elements
`which are attached directly to the roof structure By selective
`combination of at
`least two roof module elements diversely
`configured modulnr or vehicle roofs can be formed the cost
`necessary for this purpose being much less
`than if each
`desired version had to be warehoused as
`complete part
`the roof module elements which extend over
`Preferably
`the entire width of she roof ssroeture are mounsed on the
`opposing side members so dint intermediate
`elements or the
`the roof module elements are
`like are not necessary
`If
`roof can be con
`detachably mounted mounted modular
`vened by replacement of die roof module elements
`roof
`Variability of the modular
`is ensured by she cross
`members and
`she side members bordering
`roof structure
`opening which can be closed partially or completely by at
`least two roof module elements
`roof opening which remains between two roof module
`elements or between one roof module element and one cross
`
`25
`
`40
`
`45
`
`50
`
`ii
`
`so
`
`so
`
`respective
`cross frame elements extending over the entire width of the
`roof structure between the two side members
`In one simple configuration the front cross frame element
`to the cross member
`can be designed for direct attachment
`and the back cross frame
`20 on she top edge of the windshield
`to the cross member on the
`element for direct attachment
`edge of she rear window
`Preferably each frame element which is attached direcdy
`to the assigned member of the roof structure has means so
`that with the interposition of
`flange which
`seal
`it rests on
`is provided on the inside of the member
`Feasibly the sliding roof unit can be attached to the roof
`partial system which is completely prefabri
`cated with an inner
`each roof module
`lining In general
`element which contains additional
`components can be pre
`installation on the vehicle roof
`
`sop
`
`is
`
`structure as
`
`fubricated so that
`
`final
`
`simplified
`
`in motor vehicle with an espe
`To achieve this
`object
`modular
`roof
`cially sheet metal roof structure for holding
`which is made according to the aforementioned
`statements
`the motor vehicle in
`respective modular
`is proposed that
`roof holds altematively an openable roof unit which is
`installed between
`roof module element and
`back
`front
`roof module element ur an openable roof unit which is
`installed between the front cross member and the back roof
`module element or an openable roof unit which is installed
`between the back cross member and
`front roof element or
`the front cross member and that she openable roof unit
`sliding roof unit
`of
`the invention
`Embodiments
`in detail
`are explained
`below with reference to the accompanying drawings
`
`it
`
`especially
`
`is
`
`BRIEF DESCRIPTION
`
`OF THE DRAWINGS
`
`is
`
`roof structure of
`
`FIG
`schematic top view of
`modular
`roof of motor vehicle
`FIG is
`schematic perspective view of the installation
`of
`roof module
`elements
`sliding roof unit and other
`according to one embodiment of this invention
`FIG is
`view similar to FIG of another embodiment
`of this invention
`FIG is an enlarged sectional view along section plane
`IVIV in FIG
`shown in FIG
`of the embodiment
`FIG is an enlarged sectional view along section plane
`VV in FIG
`shown in FIG
`of the embodiment
`FlU is an enlarged sectional view atong section plane
`VI in FIG of she embodiment
`shown in FIG
`FIG
`view similar to FIG
`shown in FIG
`FIG
`modular
`
`VI
`
`is
`
`of
`
`the embodiment
`
`in views SA SB and SC three different
`shows
`roofs of this invention
`for the same saotor vehicle
`
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`US 7077462 BI
`
`FIG
`
`in views 9A 98 and 9C schematic
`shows
`to the modular
`perspectives which correspond
`respectively
`roofs of FIGS SA 88 and SC
`FIG 10 is
`
`perspective overhead view of the shell of
`
`motur vehicle with
`roof structure for the modular roof
`FIG 11 shows in views ha lid and ilc
`made of dillërent roof module elements
`
`modular mof
`
`DETAILED DESCRIPTION
`INVENTION
`
`OF THE
`
`with modular mof
`The shell of motor vehicle
`contains mof structure
`see FIG and FIG 10 with
`fmnt cmss member
`on the top edge of the windslsield
`hack cross member
`top edge of the rear window and
`on the
`left side member
`The members
`right and
`and
`and
`surround the roof structure opening 35 of the shell
`The reference direction which corresponds to the forward
`direction of motion of the motor vehicle
`is shown sche
`matically by the arrow la in FIG
`Roof module elements such as for example the front roof
`14 sec FIGS
`module element
`lId and
`back roof
`IS and
`sliding roof unit
`supplement and
`roof in
`complete the modularly built modular
`selectively
`especially the front and the back roof
`fixable arrangement
`module element 14 and 15 being available and installable in
`different
`sizes
`
`module element
`
`contains
`
`frame
`
`see FIG
`back cross frame element
`
`The sliding roof unit
`front and
`which is formed by
`left side frame element II and
`right and
`and 10 and by
`12
`sliding roof cover 13 is movably
`supported on the
`frameS These sliding
`roofs are known and therefore are not
`explained in detail Each of the side frame elements II 12
`contains means for attaching this frame element II 12 to the
`assigned side member
`of the roof structure and each of
`the cross frame elements
`10 extends between the two side
`members
`the entire width of the roof structure
`
`to
`
`15
`
`20
`
`25
`
`30
`
`7b see FIGS SB and 98 is
`The roof module element
`connected to
`tront and
`back roof module element 141 and
`lengths which essentially
`of the roof structure
`7C1 see FIGS SC and 9C1
`top part of the modular roof
`the entire
`roof nindule elemeot 15C which
`is for example necessary to produce the connection
`to the
`rear hatch
`
`lSb of smaller
`members
`
`and
`
`The roof module element
`forms essentially
`There still
`remains
`
`back
`
`cover
`
`the cross
`
`The roof module
`
`front and
`
`element 7C2 see FIG 9C2 forms
`top part of the roof The connections
`essentially the entire
`between the roofmodule element or the
`sliding roof unit 7C5
`or 7C2 to the windshield and optionally to the rear window
`can be produced in any known manner
`FIGS ha lid and lIc again show three embodiments of
`have
`she raodutar roof The rnortitar roof can selectively
`cover 36 which closes the entire roof structure opening 35
`sheet metal or glass cover FIG ha
`for example
`roof FIG lid contains
`second veraion of the modular
`back fixed roof module element 14 and 15 and
`located in between
`the back roof
`sliding roof unit
`15 being much larger
`module element
`module element 14
`third versino of the modular roof
`FIG llc contains
`back fixed roof module
`element
`14 and
`15 which have
`the same size
`roughly
`sliding roof unit
`located in between and another cover 37
`which can be
`sliding roof cover
`fixed cover or
`As is shown in FIGS to
`each frame element
`ohich is anached directly to the corresponding member
`to
`of the roof structure
`comprises means so that with the
`seal 17 it can rest on
`flange 18 which is
`interposition of
`provided on the inside of the membera
`In the embodiment shown in FIG
`the front roof module
`the front cross member
`and
`reinfore
`element 14 covera
`19 which it attached to the back end of the front
`sheet
`ing
`14 and forms the flange 18 The front
`roof module element
`end of the front cross frame element
`ends with
`covering
`flange IS and which
`20 which is essentially parallel
`folded-down
`front edge 21 which rests on the flange
`baa
`18 its pressing on
`seal The
`ecment strip 17 which forms
`cemeot
`strip 17
`for example
`polyurethane
`headliner
`lining 22 on the
`visible prefabricated
`front cross frame element covera
`drive motor 23 and cables
`24 25 for driving the movable cover 13 of the sliding roof
`unit
`
`than the front roof
`
`front and
`
`to 12
`
`to the
`
`cement
`
`contains
`
`50
`
`In the embodiment
`
`shown in FIG
`the side frame
`element 12 of the frameS which is located exactly over the
`left side member
`flange IS of the front
`on the bottom of
`20 bears
`cement strip 17 which is not yet
`the covering
`unit 26 which forms the side guide rail
`pressed together
`of the sliding roof cover 13 is covered laterally towards the
`visible surface which is
`vehicle interior by wall 27 with
`fabric 28 The
`covered in the conventional manner with
`headlining 29 which comprises
`for example one or more
`handles and one or more airbags not shown is mounted in
`the conventional manner on the side member
`In the embodiment shown in FIG the back roof module
`element 15 on its bottom compn sea
`ribbed reiolbrcement
`so 30 which together with the roof module element 15 forms
`flange 15 The visible prelhbrtcated headtiing 31 is
`the
`cross frame element 10
`attached to the back
`
`In the embodiment shown in FIG
`the front roof module
`element 14 covers the front cross member
`which has
`rear
`5s U-shaped profile section with an end section 32 with an
`leg which runs downward and
`flange 18 which is
`outer
`then bent to the back
`
`UUSI LLC
`Exhbit 2017
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`
`over
`
`In the embodiment
`
`shown in FIG
`the sliding roof unit
`is installed between the front
`roof module element 14 and
`
`40
`
`In the embodiments
`roof structure
`
`front
`
`In this
`
`the back roof module element 15 which are attnched to the
`front cross member
`cross member
`or the back
`in FIG the
`abown schematically
`sliding roof unit 16 with
`contains
`which is directly attached to the front
`cross frsune element
`cross member
`and with
`back
`cross frame element
`10
`which is directly attached to the back cross member
`case the transition betweeo the sliding roof unit 16 and the
`rear window can be made in any manner
`The roof structure
`can also comprise several aliding roof
`modular
`they have
`roof
`for producing
`units
`different
`lengths in the lengthwise direction of the vehicle so that they
`can be connected to front and back roof module elements 14
`15 of different dimensions and in the case of direct attach
`and 10
`ment of the front or the back cross frame element
`to the front cross member
`or to tbe back cross member
`these roof module elements 14 15 can be omined
`FIGS SA SB SC and 9A 98 9C5 and 9C show three
`embodimeott of modular
`roofs for the same motor vehicles
`
`The roof module element 7a which forms the sliding roof
`unit and which is shown sebensatically in FIGS SA and 9A
`covera
`small portion for example roughly one third of the
`roof or the roof structure opening 35
`surface of the modular
`is connected to the front
`roof ntodule element 14a and the
`ISa of relatively
`
`It
`
`hack
`
`roof module element
`
`great length
`
`Page 8
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`

`

`US 7077462 BI
`
`it can
`
`first
`
`the front
`
`16 is prefabricated such that
`The sliding roof unit
`be mounted on the roof atructure opening 35 of
`vehicle
`complete modular parts system which ia provided with
`as
`an inner headlining
`in FIGS and
`As is shown achematically
`roof module clement 14 and the back roof module element
`15 if this is present are mounted
`Thereupon
`the sliding
`arrow 33 in
`roof unit
`16 is placed on the roof structure
`FIG Then the front headlining 22 the aide headlining 29
`the back headlining 31 arrows 34 can be mounted
`and
`Thus the described modular
`roof of simple structure has
`roof module elements which can
`be located and can be
`attached directly to the side roof members
`of
`example sheet metal roof structure
`elements
`front and/or
`for example
`
`of the for
`and other
`
`vehicle
`back
`roof module
`
`roof easily
`
`element
`14 and 15 can be added to the modular
`dnd economically
`such
`The linings optionally with additional
`romponents
`sunshade handles etc can then he mounted in the
`as
`conventional manner
`modular mnf enables
`reduction of
`Such
`installation
`and investment
`costs offers the advantages of modularity
`with the
`same vehicle
`and
`thus more
`type and larger
`efficient opening of the sliding roof by there being complete
`to the execution of the inner
`freedom with respect
`structural
`and outer shapes
`The conventional
`
`to seals water
`
`interfaces with respect
`drain tubes and means for
`the movable cover can
`adjusting
`also be reduced by such modular roof
`Such modular roof enables simple installatiun of accea-
`sories such as
`for example an antenna
`an operating
`cable harness etc
`console or
`This invention
`limited to the described embndi-
`is not
`can
`ments but rather numerous modifications
`and changes
`be undertalcen without going beyond the framework of the
`invention
`
`claim
`
`Modular
`
`at
`
`is
`
`least
`
`roof for motor vehicle with
`ronfatrocture
`back crnss member and
`front and
`right and
`shell having
`left side member comprising
`two roof module
`elements
`each of which
`least
`individually detachably mounted directly on at
`the cross and the
`one of
`side members of
`the roof
`strocture shell for enabling conversion of the roof from
`least one of the
`one type tn another by replacement of at
`mndule elements with one or more of
`plurality of
`types of module elements
`
`other different
`
`wherein the cross members and the side members border
`roof opening of the roof structure shell
`wherein she roof module elements extend over the entire
`width of the roof opening and
`wherein the at
`two roof module elements at
`least
`partially close said roof opening
`Modular
`roof as claimed in claim
`third roof module element
`is provided for
`portion
`closing
`of the roof opening which remains between the two roof
`module elements
`
`wherein at
`
`least
`
`least
`
`Modular roof as claimed in claim
`
`wherein at
`
`least
`
`third roof module element
`is provided for closing
`portion
`of the roof opening which remains between one of the roof
`cross member of the roof structure
`module elements and
`
`shell
`
`Modular
`roof as claimed in claim
`wherein the roof
`module elements comprise at
`least one of opaque covers
`transparent covers and fbnctional
`roof parts
`
`Modular
`roof as claimed
`in claim
`wherein
`roof parts comprise openable sunroof unita
`Modular
`roof as claimed in claim wherein the roof
`is made of sheet mcsal
`
`fimetional
`
`structure shell
`
`said
`
`Modular
`
`roof module elements is
`
`roof aa claimed in claim wherein one of the
`sliding mof unit with mounting
`
`frame
`
`Modular
`roof as claimed
`in claim
`wherein
`frame of the sliding roof unit comprises
`mounting
`10 and
`cross frame element and
`right and
`back
`frame element
`
`the
`
`front
`
`left side
`
`15
`
`wherein
`cover
`supported on the mounting
`is movably
`frame wherein each of the side frame elements com
`prises means fur attaching thereof
`side
`member and
`wherein each of the cross frame elements extends over the
`
`respective
`
`to
`
`entire width of the roof ststcture shell between the side
`members
`
`20
`
`25
`
`30
`
`is
`
`to the
`
`rear
`
`the
`
`prefabricated
`
`inner
`
`roof as claimed in claimS wherein the at
`Modular
`least
`two roof module elements are replaceable by said sliding
`roof unit and wherein
`front cross frame element
`the
`to the front cross member
`adapted for direct attachment
`which is located at
`top edge of windshield
`and the back
`is adapted for direct attachment
`cross frame element
`back cross member which is located at
`top edge of
`window
`10 Modular
`roof as claimed in claim
`wherein each of
`said frame elements comprises means for resting of
`flange
`respective cross member of the roof
`on an inner side of
`of
`seal
`structure shell with she interposition
`11 Modular
`roof as claimed
`in claim
`wherein
`is attachable to the roof structure shell as
`sliding roof unit
`partial system which is provided with
`headlining
`12 Motor vehicle with
`sheet metal roof structure shell
`back cross member and
`right and
`front and
`having
`left
`side member defining
`single roof opening and modular
`least two roof module elements
`roof unit having at
`each of
`40 which is individually detachably mounted directly on the
`roof strocture by having been lowered onto an upper side of
`each side member so as to close thu roof opening
`wherein one of the roof module elements is
`sliding roof
`unit with mounting frame
`wherein
`frame of
`
`sliding roof unit
`the mounting
`front and
`back cross frame element and
`comprises
`right and
`left side frame element
`
`the
`
`50
`
`50
`
`65
`
`wherein
`
`cover
`
`is movably
`
`supported on the mounting
`
`frame
`
`wherein each of the side frame elements cosnprises sneans
`respective side member
`for attaching thereof
`In
`wherein each nf the cross frame elements extends over the
`entire width of the roof structure shell between the side
`members and
`
`is installed in one of several
`wherein the sliding roof unit
`sltcmatively usable positions within the roof opening
`relative to another of the roof module elements
`the
`front cross member
`and the back cross member the
`roof being
`from one configuration
`convertible
`to
`another by replacement or positional
`exchange of the
`roof module elements
`13 Modular
`roof as claimed in claim wherein the roof
`number of different module
`module elements comprise
`least two roof module
`elements which is greater than the at
`elements which are mountable
`on the roof structure
`module elements being mountable
`in alteraative
`
`arrange-
`
`said
`
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`

`

`US 7077462 Bi
`
`that
`
`is
`
`ments and combinations
`involving
`elements
`less thao said number of
`the module
`selective combinations of at
`two
`elements whereby
`rnnf elements enable diversely
`configured modular vehicle
`roofs tu be provided
`
`said plurality of module
`
`least
`
`14 Motor vehicle according to claim 12 wherein the one
`of the alternatively
`usable positions in which the sliding roof
`
`unit
`
`is installed is between
`
`front roof module element and
`
`back rouf module element
`15 Motor vehicle according to claim 12 wherein the one
`of the alternatively
`usable positions in which the sliding roof
`is installed is between the front cross member and
`roof module element
`
`back
`
`unit
`
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`