Roof module for the roof of a passenger car

Abstract

Roof module for a vehicle roof of a passenger car, comprising a roof module frame (1) in which a drive system for moving the roof section is provided, which has two flexible drive transmission cables (2) operatively connected to the roof section, and in which guides (3) for the two drive transmission cables (2) and a bearing area (6) for a drive pinion cooperating with the drive transmission cables (2) are provided, and a retaining part (7, 7a to 7b) which guides and supports the drive transmission cables (2) laterally outside in the bearing area (6) for the drive pinion, wherein the retaining part (7, 7a to 7b) is designed as a sheet metal component which has a top surface (10, 10a to 10b) and a parallel spaced-apart bottom surface (11, 11a to 11b), both of which are circularly recessed corresponding to a base area of ​​the drive pinion, and which are supported by opposing side support areas (15, 15a to 15b) are connected to each other,which each guide and support a drive transmission cable (2) laterally on the outside, characterized in that the retaining part (7, 7a to 7b) is designed in a ring-shaped closed form, and that the retaining part (7, 7a to 7b) is bent upwards in a conical manner at its - viewed in the longitudinal direction - opposite end edge regions (14, 14a to 14b).

Description

[0001] The invention relates to a roof module for a vehicle roof of a passenger car according to the preamble of claim 1.

[0002] Such a roof module is known from DE 20 2007 019 262 U1. The known roof module has a drive system with drive transmission cables that are guided laterally outwards and supported by a retaining element in a bearing area for the drive pinion. The retaining element is designed as a sheet metal component with a top surface and a parallel, spaced-apart bottom surface. Both the top surface and the bottom surface have circular cutouts corresponding to the base area of ​​a drive pinion of the drive system.

[0003] DE 44 19 175 C1 also discloses a holding part, but not with a bottom surface, but with a free edge projecting vertically downwards.

[0004] Another roof module is known from WO 2013 / 007477 A1. This known roof module comprises a roof module frame and a roof section that is movable relative to the roof module frame between an open and a closed position. The roof section is operatively connected on its opposite sides via a control mechanism to a drive transmission cable of a drive system. The drive transmission cables are flexible and have a helical or threaded outer contour in the area of ​​their sheath. The drive transmission cables move synchronously with each other. For this purpose, a drive pinion is provided with which both drive transmission cables mesh. The drive pinion is driven by an electric motor.A rotation of the drive pinion consequently causes opposing movements of the drive transmission cables, resulting in synchronous longitudinal displacements of the respective control mechanism and, consequently, the movable roof section. The two drive transmission cables interact with the drive pinion on opposite tangential sides of the pinion, with the respective threaded or helical sheath of each cable engaging with corresponding teeth on the drive pinion. To prevent the drive transmission cables from deflecting radially outwards from the drive pinion's axis of rotation due to their flexibility, a retaining element is provided in the bearing area of ​​the drive pinion. This retaining element is designed as a U-shaped, upwardly open sheet metal part.The sheet metal part has side legs that radially support and guide the respective drive transmission cable at the level of the engagement area with the drive pinion.

[0005] The object of the invention is to create a roof module of the type mentioned above that is easy to install and enables reliable drive transmission.

[0006] This problem is solved by the features of claim 1. The circular recesses in the base and top surfaces of the retaining part allow the drive pinion to be mounted only after the retaining part and the drive transmission cables have been installed in the bearing area. This significantly reduces the assembly and adjustment effort for the roof module frame and the roof module. Because the retaining part is closed in an annular shape, the drive transmission cables are supported and secured on all sides in the engagement area with the drive pinion, thus reliably preventing the drive transmission cables from detaching from the drive pinion.

[0007] The solution according to the invention is provided for a roof module of a passenger car roof, which is at least largely pre-assembled before being positioned at a corresponding cutout in the vehicle roof and firmly and tightly connected to corresponding body support structure components of the vehicle roof and to the outer skin of the vehicle roof. In the installed state, a surface of the roof module is flush with the edge areas of the vehicle roof that define the roof cutout. For final assembly, only simple final assembly steps such as electrical connections to the vehicle's electrical system, attaching an interior roof lining in the area of ​​the vehicle interior headliner, and similar tasks need to be carried out after the roof module has been installed.

[0008] In one embodiment of the invention, the roof module frame has locking points in the storage area for mounting the sheet metal component, and the sheet metal component is provided with complementary locking means that positively secure the sheet metal component in the storage area when mounted. This makes it possible to mount the sheet metal component to the roof module frame or, if necessary, to dismount it again without tools.

[0009] In a further embodiment of the invention, the outer contours of the side support areas of the sheet metal component are designed as locking elements. The outer contours are preferably curved in an arc, so that complementary locking points in the area of ​​the roof module frame result in a positive-locking engagement of the outer contours of the side support areas. The locking points in the area of ​​the roof module frame are preferably formed integrally with the roof module frame.

[0010] In a further embodiment of the invention, the top surface and the bottom surface are designed to be flat, and the side support areas are convex – in cross-section – curved, in particular in a circular arc shape. The flat design of the bottom surface enables a flat bearing surface on a floor of the storage area of ​​the roof module frame.

[0011] In a further embodiment of the invention, the sheet metal component is designed as a single piece. Consequently, the sheet metal component can be handled as a single unit. In a further embodiment, the sheet metal component is manufactured either from a single sheet metal part or from several sheet metal parts. Advantageously, the sheet metal component is constructed from a maximum of two sheet metal parts, which are processed by cold forming and cutting processes to form the sheet metal component.

[0012] In a further embodiment of the invention, the sheet metal parts are joined to each other at their joints by butt jointing or overlapping, forming a material bond. A material bond is understood to mean welding, soldering, or bonding. Overlapping means that edge regions of the sheet metal parts overlap and the material bond is provided in the area of ​​the overlapping edge sections. Butt jointing means that the edge regions lie flush against each other in a common plane and are materially bonded to each other at their end faces.

[0013] In a further embodiment of the invention, the sheet metal component is provided with longitudinally extending incisions on its opposite end edges, which form flared tabs at the end edges. This allows the end edges of the sheet metal component to be deformed in the area of ​​the flared tabs, which can serve to clamp guide sleeves for the drive transmission cables or to additionally secure the sheet metal component to the roof module frame.

[0014] Further advantages and features of the invention will become apparent from the claims. Preferred embodiments of the invention are described below and illustrated with reference to the drawings. Fig. Figure 1 shows an enlarged section of a front area of ​​a roof module frame of an embodiment of a roof module according to the invention for a vehicle roof of a passenger car. Fig. 2 in perspective view a holding part with two drive transmission cables of the roof module to Fig. 1, Fig. 3 in enlarged perspective view the holding part according to Fig. 2, Fig. 4 another embodiment of a retaining part for a roof module according to the Fig. 1 and Fig. 2 similar Fig. 3, Fig. Figure 5 shows a further embodiment of a holding part for a roof module according to the perspective view. Fig. 1 and Fig. 2, Fig. Figure 6 shows a perspective view of an embodiment of a holding part for a roof module not belonging to the invention. Fig. 1 and Fig. 2 and Fig. 7 another embodiment of a retaining part for a roof module, not belonging to the invention according to the Fig. 1 and Fig. 2, which is similar Fig. 6 is designed.

[0015] A passenger car has a roof, in a generally known manner, which is cut out to accommodate a roof module according to one embodiment of the invention. The roof module has a roof module frame 1, which, in its installed state, is firmly and tightly connected to corresponding edge regions of the vehicle roof. The roof module frame has guide rail arrangements on opposite longitudinal sides, in each of which a guide and control mechanism is longitudinally displaceable. The two opposing guide and control mechanisms are each connected to a movable roof section, which can be moved between a closed and an open position in the longitudinal direction of the passenger car. In its closed position, the movable roof section closes a roof opening that is at least partially bounded by the roof module frame 1. On the front side, i.e.,In the normal direction of travel, in front of the roof opening, two drive transmission cables 2 of a drive system are laid. In the front area of ​​the roof module frame 1, the middle area of ​​which is in . Fig. As shown in Figure 1, an electric drive motor of the drive system is positioned, which is operatively connected to the drive transmission cables 2 via a drive pinion (not shown). Each drive transmission cable 2 is designed as a flexible threaded shaft, also referred to as a flex shaft. The threaded shaft has a helically shaped outer sheath that meshes with the drive pinion of the drive motor and is thereby longitudinally displaced in corresponding guides 3 for the respective drive transmission cable 2. By correspondingly displacing the compression- and tension-resistant drive transmission cable 2, the corresponding guide and control mechanism on each side of the movable roof section is actuated. The respective drive transmission cable 2 is guided longitudinally in hose- or tube-shaped guides 3.

[0016] In the area of ​​the drive pinion (not shown), the two drive transmission cables 2 are guided parallel to each other on opposite sides of the drive pinion, each passing tangentially. The drive pinion's teeth engage positively with the threaded outer sheath of the respective drive transmission cable 2. In the area of ​​the drive pinion, the drive transmission cables 2 run transversely to the vehicle and thus perpendicular to the guide rail arrangements for the movement of the control and guide mechanisms, and thus for the movement of the movable roof section, which extend longitudinally along the vehicle. As can be seen from the Fig. As can be understood, when the drive pinion, which is located in a bearing area 6 of the roof module frame 1, rotates, the opposing drive transmission cables 2 move in opposite directions to each other. This inevitably results in a synchronous parallel displacement of the end sections of the drive transmission cables, which are connected to the control and guide mechanisms, after the opposing drive transmission cables 2 are deflected to the opposing guide rail arrangements. Consequently, the roof section is also inevitably displaced parallel to each other, either to the rear or to the front in the longitudinal direction of the vehicle.

[0017] In the circular bearing area 6, the drive pinion is positioned such that its axis of rotation extends upwards in the vehicle direction and thus perpendicular to a plane that accommodates the two drive transmission cables 2 within the bearing area 6. Extending downwards from this axis of rotation, the drive pinion is connected, in a manner not shown in detail, to a suitable gearbox of the drive motor, which rotates the drive pinion accordingly.

[0018] To prevent the two drive transmission cables 2, which are exposed in bearing area 6 (i.e., in the area of ​​the drive pinion), from being pushed radially outwards towards the axis of rotation of the drive pinion when the drive pinion rotates, a retaining element 7 is provided in bearing area 6 of the roof module frame 1. This retaining element 7 is described in detail below. The retaining element 7 is ring-shaped and has a flattened bottom surface 11 and a flattened top surface 10. The retaining element 7 encloses the parallel drive transmission cables 2 on their outer sides facing away from the drive pinion, as shown by the Fig. 1 and Fig. 2 can be easily removed. For this purpose, the retaining part 7 has lateral support areas 15 that extend parallel to the respective drive transmission cable 2. In plan view, the retaining part 7 has a substantially rectangular base. The retaining part 7 has the shape of a flattened sleeve. Both the top surface 10 and the bottom surface 11 are each provided with a circular recess 12, 13, the diameter of which is at least as large as an outer diameter of the drive pinion (not shown). The drive pinion can therefore be inserted from above or from below through the top surface 10 or the bottom surface 13 into the common plane of the two drive transmission cables 2 in the bearing area 6.In particular, it is possible to guide a bearing shaft of the drive motor gearbox, onto which the drive pinion can be mounted in a rotationally locked manner, upwards from below through an opening in the base of the roof module frame 1, so that the bearing shaft projects into the circular recesses 12 and 13 of the retaining part 7 in the bearing area 6. The drive pinion can then be placed onto the bearing shaft from above through the cover surface 10.

[0019] In an embodiment of the invention not shown, only one of the two surfaces is provided with a corresponding circular recess.

[0020] For the purpose of securing the retaining element 7 in the roof module frame 1, which is made of plastic in the front area shown, detent points 8, 9 are integrally formed on the roof module frame 1, between which the retaining part 7 is inserted according to Fig. The retaining part 7 can be snapped into place, i.e., clipped into position. The retaining part 7 can be pre-assembled together with the drive transmission cables 2 and the corresponding hose- or tube-shaped guides 3 for the drive transmission cables 2, so that the unit consisting of the retaining part 7, the drive transmission cables 2, and the associated guides 3 can be inserted into corresponding, unspecified profiles of the roof module frame 1 and secured there. Alternatively, it is possible to fix the retaining part 7 between the locking points 8, 9 on the roof module frame 1 before mounting the drive transmission cables 2 and then thread the drive transmission cables 2 through the retaining part 7.

[0021] Both the top surface 10 and the bottom surface 11 of the retaining part 7 are flat and aligned parallel to each other. The side support areas 15 connect the bottom surface 11 and the top surface 10 over the entire length of the retaining part 7 – in the longitudinal direction of the drive transmission cables 2 according to Fig. 2 seen - continuously connected. At its longitudinally opposite end-edge regions 14, the retaining part 17 is bent upwards in a conical shape. This allows for improved positioning within corresponding profiles of the roof module frame 1, which are based on the Fig. 1 are recognizable, but not further specified.

[0022] Between the top surface 10 and the bottom surface 11, there is therefore a space that is open continuously to both long sides, and which is also open upwards and downwards in the area of ​​the circular recesses 12, 13.

[0023] The retaining part 7 according to the Fig. Parts 1 to 3 are designed as a single-piece sheet metal component, manufactured primarily by deep drawing in the form of a flat sleeve. Alternatively, the sheet metal component can also be designed as a drawn tube. The two circular recesses 12 and 13 are created by subsequent machining, particularly by drilling or milling, of the top surface 10 and the bottom surface 11. Both the top surface 10 and the bottom surface 11 each form a plate of uniform thickness. The wall thickness of the entire sheet metal component is constant across its entire surface area. Alternatively, the wall thickness can also vary.

[0024] The retaining part 7a according to Fig. 4 is also designed as a sheet metal component and has a shape that is essentially the same as the shape of the retaining part 7. Fig. 3 corresponds. The retaining part 7a is used in the same way on a roof module, as shown by the Fig. 1 and Fig. 2 is recognizable and has been described previously. The essential difference in the retaining part 7a is that the retaining part 7a was not formed by deep drawing, but rather by cold forming and welding in the area of ​​connection points 16a. For this purpose, the retaining part 7a consists of two sheet metal parts, namely an upper half and a lower half as shown. Fig. 4, each of which is designed in a semi-shell shape. The upper and lower sheet metal parts are positioned offset from each other at their side support areas 15a and are bonded together along the entire length of the retaining part 7a in the area of ​​the side edges. In the illustration according to Fig. 4. Consequently, the upper half, which comprises the top surface 10a, extends laterally beyond the right side edge of the lower half, which contains the bottom surface 11a, with its right side edge extending outwards. The left side edge of the upper half, however, is positioned within the left side edge of the lower half. The end edges of the opposing sheet metal parts therefore overlap in the area of ​​these side support areas 15a and are continuously bonded along their entire length, in particular by welding or brazing. The two half-shells were previously manufactured from a single flat sheet metal part by cold forming. The circular recesses 12a and 13a were created by separating machining analogous to the retaining part 7. Fig. 3 created.

[0025] The retaining part 7b after Fig. 5 is also designed as a sheet metal component from two sheet metal parts, with an upper sheet metal part, which defines the top surface 10b, abutting its side edges against corresponding side flanges of the lower sheet metal part, which defines the side support areas 15b and the bottom surface 11b. Here, too, a continuous, material-bonded connection is made in the area of ​​the linear connection point 16b, so that the retaining part 7b can be handled as a single-piece sheet metal body. Corresponding end edge areas 14b of the retaining part 7b are slightly projected outwards.This results in a notch 17b on opposite sides between the upper sheet metal part and the end edge area of ​​the lower sheet metal part, through which the upper area of ​​the end edge area 14b can be extended diagonally upwards as a wide tab, without affecting the lower part of the end edge area 14b of the lower sheet metal part.

[0026] In the embodiment according to Fig. 6. The retaining part 7c is largely identical in its basic form to the retaining part 7 according to the Fig. 1 to 3. The retaining part 7c is a sheet metal component manufactured from a single sheet metal part by appropriate cold forming, i.e., bending. Opposing end-edge areas of the sheet metal part overlap each other in the area of ​​the upper cover surface 10c and are metallurgically joined together at the overlapping connection points via a weld point 18c.

[0027] In all embodiments, identical or functionally equivalent sections are designated with the same reference numerals, with the addition of appropriate letters for the different embodiments.

[0028] The longitudinally extending end edges 14c of the retaining part 7c are provided with various incisions 17c, resulting in several projection tabs 19c, which according to the illustration Fig. 6 are positioned diagonally outwards.

[0029] The retaining part 7d according to Fig. 7 essentially corresponds to the holding part 7c according to Fig. 6 with the sole difference that the retaining part 7d is joined together from two sheet metal parts to form the one-piece metal sheet component.

[0030] While in the embodiments according to the Fig. 4 and Fig. Since the corresponding parting lines between the two sheet metal parts run approximately horizontally, the parting line between the two sheet metal parts of the retaining part 7d runs vertically in the longitudinal direction of the retaining part 7d. This also applies to the embodiment according to Fig. 7 The corresponding end-edge areas of the sheet metal parts overlap each other in the area of ​​the connection points 16d and are each materially bonded to one another via weld points 18d. The cutouts 17d and the resulting flared tabs 19d are designed identically to those of the retaining part 7c.

Claims

[1] Roof module for a vehicle roof of a passenger car, comprising a roof module frame (1) in which a drive system for moving the roof section is provided, which has two flexible drive transmission cables (2) operatively connected to the roof section, and in which guides (3) for the two drive transmission cables (2) and a bearing area (6) for a drive pinion cooperating with the drive transmission cables (2) are provided, and a retaining part (7, 7a to 7b) which guides and supports the drive transmission cables (2) laterally outside in the bearing area (6) for the drive pinion, wherein the retaining part (7, 7a to 7b) is designed as a sheet metal component having a top surface (10, 10a to 10b) and a parallel spaced-apart bottom surface (11, 11a to 11b), both of which are circularly recessed corresponding to a base area of ​​the drive pinion, and which have opposing side support areas. (15, 15a to 15b) are connected to each other,each of which guides and supports a drive transmission cable (2) laterally on the outside, , characterized by , that the retaining part (7, 7a to 7b) is designed to be ring-shaped and that the retaining part (7, 7a to 7b) is bent upwards in a conical shape at its opposite end-edge regions (14, 14a to 14b) when viewed in the longitudinal direction. [2] Roof module according to claim 1, characterized by , that the roof module frame (1) has locking points (8, 9) in the storage area (6) for mounting the sheet metal component, and that the sheet metal component is provided with complementary locking means that secure the sheet metal component in the storage area (6) in a form-fitting manner when mounted. [3] Roof module according to claim 2, characterized by , that the outer contours of the side support areas (15, 15a to 15b) of the sheet metal component are designed as locking means. [4] Roof module according to claim 1, characterized by, that the top surface (10, 10a to 10b) and the bottom surface (11, 11a to 11b) are flat, and that the side support areas (15, 15a to 15b) - seen in cross-section - are convex, in particular curved in a circular arc. [5] Roof module according to any one of the preceding claims, characterized by that the sheet metal component is designed as a single piece. [6] Roof module according to claim 5, characterized by that the sheet metal component is made from a single sheet metal part or from several sheet metal parts. [7] Roof module according to claim 6, characterized by , that the sheet metal parts are butted together or overlapping at their joints (16a, 16b) in a material-bonded manner. [8] Roof module according to one of claims 5 to 7, characterized by, that the sheet metal component is provided on its opposite end edges (14b) with longitudinally extending incisions (17b) which form flared tabs (19b) on the end edges.

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