VEHICLE ROOF WITH ROOF ELEMENT AND METHOD FOR PRODUCING A VEHICLE ROOF ELEMENT

Description

[0001] The invention relates to a vehicle roof having the features of the preamble of patent claim 1 and a method for producing a vehicle roof element.

[0002] A vehicle roof is known in practice that comprises a fixed roof element as the outer skin element, which is rigidly arranged relative to a vehicle superstructure or vehicle body and has a flat panel made of glass, plastic, or sheet metal. A connecting plate is attached to the panel via a molded section made of polyurethane foam. The connecting plate makes it possible to firmly attach the roof element to the body. The connection of the connecting plate to the panel has previously been carried out in a molding tool that has a cavity for forming the molded section. Such a molding tool is expensive, which in turn is reflected in the cost of the resulting vehicle roof.

[0003] Alternatively, it is known to provide a glass panel, which is part of a fixed roof element, with a polyurethane foam frame, which is used to connect it to a vehicle body shell. To produce the frame, a mold with a cavity is used, the walls of which are coated with a release agent. However, in order to be able to bond the polyurethane foam frame to the vehicle body shell, it is necessary to remove any release agent residues after production and thus mechanically prepare it for the bonding process, which can be complex. The release agent in the mold is required, however, in order to be able to demold the molded section produced in the mold.

[0004] From the publication US 2010 / 0276969 A1, a roof element of a motor vehicle is known, comprising a flat panel, on the inside of which inner cover panels are arranged, each having flanges bonded to the panel via adhesive tape. A cavity filled with PU molding material is formed between each inner cover panel and the panel. During production, the PU molding material is introduced into the cavity through a hole in the respective inner cover panel. Air is expelled from the cavity through a second hole in the inner cover panel.

[0005] The invention is based on the object of creating a vehicle roof with a roof element which can be produced cost-effectively and which can be connected to a vehicle body without further pretreatment, as well as a method for producing such a vehicle roof element.

[0006] This object is achieved according to the invention by the vehicle roof having the features of patent claim 1 and the method having the features of patent claim 10.

[0007] The invention therefore proposes a vehicle roof comprising a roof element having a flat panel made of glass, plastic, or sheet metal, and a connecting plate that is connected to the inside of the panel via a molded section. The connecting plate rests loosely and sealingly on the inside of the panel via contact flanges and, together with the inside of the panel, defines a cavity filled by the molded section that holds the connecting plate to the panel. The connecting plate is free of molded sections on its surfaces located outside the cavity, i.e. the material that fixes the connecting plate to the panel is contained only in the cavity.

[0008] In the vehicle roof according to the invention, no complex molding tool is required to form a cavity for the molded section. Instead, the cavity in which the molded section is formed is defined by the roof element itself, i.e. by the flat panel and the connecting plate. Such roof elements can be manufactured with short cycle times. Since the connecting plate can be connected directly to a vehicle body, there is no need for complex post-processing of the panel provided with the connecting plate before assembly. Release agents within a cavity are also not required. When forming the molded section or connecting the connecting plate to the panel, the connecting plate only needs to be pressed against the inside of the panel to create sealing surfaces between its contact flanges and the panel.

[0009] The term "molded section" refers to a section of the vehicle roof according to the invention that is manufactured using a plastic molding process, in particular an injection molding process or a foaming process, in which a plastic material in a pourable form is introduced into a mold cavity and hardens there. This is the case, for example, with a RIM (Reaction Injection Molding) process. In the present case, the mold cavity is defined or delimited by the panel on the one hand and the connecting sheet on the other.

[0010] In a preferred embodiment of the vehicle roof according to the invention, the connecting plate and the cavity are designed like a frame, circumferentially following the edges of the panel. The connecting plate can thus be connected to the panel circumferentially by means of a single cavity.

[0011] In order to allow simple production of the vehicle roof according to the invention, the connecting plate expediently has two openings that connect the cavity with the environment. The sprue, i.e. the introduction of the material from which the mold section is formed, takes place through one of the openings. Ventilation during the introduction of the material takes place through the other of the openings. Air can therefore be displaced from the cavity by the introduced material. It is understood that at least in the region of one of the openings, material residues or residues are also present on the outside of the connecting plate, which are created in particular due to the tool during the formation of the mold section. Such residues or residues, which are dome-shaped or mushroom-shaped, for example, are not to be regarded as a mold section within the meaning of the invention, which is arranged on a surface of the connecting plate that lies outside the cavity.

[0012] To ensure that no material escapes from the cavity during the production of the molded section, in an advantageous embodiment of the vehicle roof according to the invention, sealing elements are arranged between the contact flanges and the panel. These sealing elements rest loosely and sealingly against the inside of the panel. There is no material bond between the sealing elements and the panel, but rather only a form fit.

[0013] In a special embodiment of the vehicle roof according to the invention, the roof element is a fixed roof element which is rigidly or non-displaceably connected to the vehicle body.

[0014] To connect the fixed roof element to the vehicle body, a special design features a circumferential adhesive surface for attachment to the vehicle body. The connecting plate can then represent an outer ring of the flat panel, which has a homogeneous, adhesive surface. The connecting plate can also increase the rigidity of the flat panel.

[0015] The adhesive surface can form a particularly step-free frame surface which encloses the flat panel and is thus arranged on the outside with respect to the center point of the flat panel.

[0016] In order to provide an assembly-friendly support and adhesive surface on the connecting plate, the adhesive surface in a special embodiment of the vehicle roof according to the invention is formed on a fold of the connecting plate that is located on the outside with respect to a center point of the fixed roof element.

[0017] In a practical embodiment, the vehicle roof according to the invention has a substructure fixed to the vehicle or body, to which the fixed roof element is attached via an adhesive bead arranged on the adhesive surface. The roof substructure can be formed by a roof frame or the like and is rigidly arranged relative to the vehicle body or body.

[0018] The connecting plate can be constructed as a single piece, i.e., manufactured as a single-piece metal stamped and bent part, which results in short cycle times. Alternatively, it is also conceivable for the connecting plate to be composed of several leg elements, which are connected to each other, for example, via welds, and form a frame-like element when assembled.

[0019] The connecting plate can also have a multifunctional function and, in addition to connecting to the vehicle body, also serve to mount a functional element. In this case, the connecting plate can have a fixing section for connecting the functional element, which can in particular be an element of a shading arrangement.

[0020] The invention also relates to a method for producing a vehicle roof element comprising a flat panel made of glass, plastic or sheet metal and a connecting plate for connecting the roof element to a vehicle body, comprising the following steps: Providing the panel; placing the connecting plate against an inner side of the panel so that a cavity is formed between the connecting plate and the panel and the connecting plate rests loosely and sealingly against the inner side of the panel via contact flanges; introducing a molding material into the cavity via a sprue opening of the connecting plate so that a mold section is formed in the cavity which alone fixes the connecting plate to the panel.

[0021] The method according to the invention can be carried out in particular in a device having a holding tool that holds the connecting sheet in a fixed position on the inside of the panel during the forming of the molded section, and is preferably additionally provided with a holding device for the panel. For example, the device comprises a lower tool that holds the panel in a fixed position and an upper tool that forms the holding tool for the connecting sheet.

[0022] In addition, the device for connecting the connecting plate to the panel preferably has a sprue device by means of which the material can be introduced into the cavity via the sprue opening.

[0023] In a special embodiment of the method according to the invention, the molding material is introduced into the cavity according to a RIM (Reaction In Mold) process, i.e. according to a process in which the material is introduced into the cavity under high pressure, where it reacts chemically and hardens.

[0024] The venting of the cavity during molding or when the molding material is introduced into the cavity can be done via a vent opening, which can also be formed on the connecting plate.

[0025] To ensure that no mold material escapes from the cavity, the contact flanges of the connecting plate can be provided with sealing elements through which they are attached to the panel.

[0026] The mold material from which the mold section is formed is in particular a polyurethane material which, after a foaming process, forms a polyurethane foam in the cavity delimited by the connecting sheet and the panel.

[0027] Further advantages and advantageous embodiments of the subject matter of the invention can be found in the description, the drawings and the patent claims.

[0028] An embodiment of a vehicle roof according to the invention is shown schematically in the drawing and is explained in more detail in the following description. It shows: Figure 1 shows a schematic plan view of a truss roof with a fixed roof element; Figure 2 shows a bottom view of the fixed roof element; Figure 3 shows a section through the fixed roof element in the edge area; and Figure 4 shows a section through the fixed roof element along the line IV-IV in Figure 2 during its production.

[0029] In Figure 1 1 shows a roof 10 of a passenger car (not shown in detail), which is designed as a panoramic roof and has a fixed roof element 12 that extends from the rear edge of the roof 10 to a central region of the roof 10. A roof opening is formed on the front side of the fixed roof element 12, which opening can be closed by means of a displaceable cover element 14. The cover element 14 can be moved by means of an adjustment kinematic (not shown in detail) between the Figure 1shown closed position and an open position in which the roof opening is at least partially released and the cover element 14 is moved over the fixed roof element 12. The Figure 2 and 3 The fixed roof element 12 shown in isolation comprises a glass panel 16, which forms an outer roof skin element and is curved. At its peripheral edge, the glass panel 16 is provided with a peripheral, frame-like connecting plate 18, which serves to fix the fixed roof element 12 to a vehicle-mounted roof substructure 20 and is a one-piece stamped and bent part made of steel or a light metal.

[0030] The connecting plate 18 comprises two frame-like support flanges 22 and 24, each provided with a sealing element 26 and 28, respectively, which rests loosely against an inner side 30 of the glass panel 16. The inner side 30 of the glass panel 16 faces a vehicle interior. On the outer side 32 facing away from the inner side 30, the glass panel 16 forms the outer visible surface of the fixed roof element 12.

[0031] Between the two sealing elements 26 and 28 or the two contact flanges 22 and 24, the connecting plate 18, together with the inner side 30 of the glass panel 16, defines a frame-like, circumferential cavity 34, which follows the course of the circumferential, frame-like connecting plate 18. The cavity 34 is filled by a molded section 36, which is formed from a polyurethane foam material and which fixes the connecting plate 18 to the glass panel 16.

[0032] To form the mold section 36, the connecting plate 18 has a sprue opening 38, which is designed in the form of a slot, on one frame leg in the area between the two contact flanges 22 and 24, and a vent opening 40 on a second frame leg.

[0033] Furthermore, the connecting plate 18 has a support flange 42 arranged externally relative to the center of the glass panel 16, on the underside of which a circumferential adhesive surface 44 is formed. The fixed roof element 12 is bonded to the roof substructure 20 via the adhesive surface 44 by means of an adhesive bead 46.

[0034] The production of the fixed roof element 12 is carried out with reference to Figure 4 in the manner described below.

[0035] In a first process step, the glass panel 16 is inserted into a holding device 52 with the inner side 30 facing upwards and secured. Subsequently, using a holding tool 54, the connecting plate 18 is pressed loosely and sealingly against the inner side 30 of the glass panel 16 via the sealing elements 26 and 28, which are attached to the contact flanges 22 and 24.

[0036] Subsequently, a foaming device 48 is brought to the gate opening 38, and a venting device 50 is brought to the vent opening 40. A polyurethane foam material is then introduced into the cavity 34 formed between the connecting plate 18 and the inner side 30 of the glass panel 16 by means of the foaming device 48, while simultaneously displacing the air from the cavity 34 via the vent opening 40 or the venting device 50. The polyurethane foam material, which forms the mold section 36 after curing, is introduced using a RIM process under high pressure. List of reference symbols

[0037] 10Vehicle roof 12Fixed roof element 14Cover element 16Glass panel 18Connecting plate 20Roof substructure 22Support flange 24Support flange 26Sealing element 28Sealing element 30Inside 32Outside 34Cavity 36Mold section 38Gating opening 40Vent opening 42Support flange 44Adhesive surface 46Adhesive bead 48Foaming device 50Venting device 52Holding device 54Holding tool

Claims

1. A vehicle roof comprising a roof element having a planar panel (16) made of glass, plastic or sheet metal, the panel having an outer side (32) facing a vehicle environment and an inner side (30) facing a vehicle interior, and the roof element having a connecting metal plate (18) connected to the inner side (30) of the panel (16) via a molded portion (36), characterized in that the connecting metal plate (18) is in loose and sealing contact with the inner side (30) of the panel (16) via contact flanges (22, 24) and defines a cavity (34) together with the inner side (30) of the panel (16), the cavity (34) being filled by the molded portion (36), and in that the connecting metal plate (18) is free from molded portions at its surfaces disposed outside the cavity (34).

2. The vehicle roof according to claim 1, characterized in that the connecting metal plate (18) and the cavity (34) are of a frame-like design and circumferentially follow the edges of the panel (16).

3. The vehicle roof according to claim 1 or 2, characterized in that the connecting metal plate (18) has two openings (38, 40) which connect the cavity (34) to the environment.

4. The vehicle roof according to any one of claims 1 to 3, characterized in that sealing elements (26, 28) are disposed between the contact flanges (22, 24) and the panel (16).

5. The vehicle roof according to any one of claims 1 to 4, characterized in that the roof element is a fixed roof element (12).

6. The vehicle roof according to claim 5, characterized in that the connecting metal plate (18) has a circumferential adhesion surface (44) for connecting the fixed roof element (12) to a vehicle structure.

7. The vehicle roof according to claim 6, characterized in that the adhesion surface (44) is formed on an underside of a contact flange (42) of the connecting metal plate (18), said contact flange being an outer contact flange with respect to a center of the fixed roof element (12).

8. The vehicle roof according to any one of claims 6 to 7, characterized by a substructure (20) which is attached to the vehicle or the body and to which the fixed roof element (12) is attached via a bead of glue (46) disposed on the adhesion surface (44).

9. The vehicle roof according to any one of claims 1 to 8, characterized in that the connecting metal plate (18) comprises a fixing portion for connecting a functional element, in particular an element of a shading assembly.

10. A method for producing a vehicle roof element having a planar panel (16) made of glass, plastic or sheet metal and a connecting metal plate (18) for connecting the roof element to a vehicle structure, the method comprising the following steps: - providing the panel (16); - attaching the connecting metal plate (18) to an inner side (30) of the panel (16) so that a cavity (34) forms between the connecting metal plate (18) and the panel (16) and the connecting metal plate (18) is in loose and sealing contact with the inner side (30) of the panel (16) via contact flanges (22, 24); and - introducing a mold material into the cavity (34) via a gate (38) of the connecting metal plate (18) so that a molded portion (36) forms in the cavity (34), the molded portion (36) alone fixing the connecting metal plate (18) to the panel (16).

11. The method according to claim 10, characterized in that the connecting metal plate (18) is pushed against the inner side of the panel (16) by means of a holding tool (54) during the molding of the molded portion (36).

12. The method according to claim 10 or 11, characterized in that the panel (16) is held in position.

13. The method according to any one of claims 10 to 12, characterized in that the mold material is introduced according to an RIM process.

14. The method according to any one of claims 10 to 13, characterized in that the contact flanges (22, 24) are provided with sealing elements (26, 28) and are joined to the panel (16) via the sealing elements (26, 28).