Ceiling member, ceiling member manufacturing method, and ceiling member fitting method

Abstract

To provide a ceiling member suitable for transporting itself by holding and hanging one side of a periphery thereof.SOLUTION: A ceiling member is a ceiling member of a vehicle, and includes a body 21 which covers a ceiling panel of the vehicle, and an extrusion part 10 which is integrated with the body 21 and has a hole. A method for manufacturing a ceiling member of a vehicle includes a step at which a body 21 which covers a ceiling panel of the vehicle and an extrusion part 10 having a hole are integrally molded.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a ceiling member, a method for manufacturing the ceiling member, and a method for installing the ceiling member.

Background Art

[0002] For vehicle assembly, a jig for transporting a ceiling member of a vehicle to a place where the installation process is performed is known. Patent Document 1 describes a jig for transporting a ceiling member in which two parts are pivotally connected to each other by a pin.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The jig described in Patent Document 1 is for lifting and transporting the ceiling member of a vehicle while it is lying flat. However, when storing the ceiling members flat without stacking them on top of each other after transportation, a larger storage space is required than when storing the ceiling members vertically. Therefore, it is advantageous to hang the hook of the transporter on one side of the outer peripheral portion of the ceiling member, suspend it, transport the ceiling member in a vertical state, place the ceiling member as it is when it reaches the installation area, and store it in a vertical state. However, there may be no appropriate location on the outer peripheral portion of the ceiling member where the hook of the transporter can be hung.

[0005] An object of the present invention is to provide a ceiling member suitable for transportation by holding and suspending one side of the outer peripheral portion.

Means for Solving the Problems

[0006] To achieve the above object, according to one aspect of the present invention, there is provided a ceiling member for a vehicle, including a main body that covers the ceiling panel of the vehicle, and a protruding portion that is integrated with the main body and has a hole.

[0007] According to another aspect of the present invention, there is provided a method for manufacturing a ceiling member for a vehicle, including a step of integrally molding a main body that covers the ceiling panel of the vehicle and a protruding portion that has a hole.

Advantages of the Invention

[0008] According to the present invention, it is possible to provide a ceiling member suitable for transportation by holding and suspending one side of the outer peripheral portion.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Modes for Carrying Out the Invention

[0010] Referring to FIGS. 1 to 3, the ceiling member according to the first embodiment of the present invention will be described. The embodiment is an exemplification of the present invention and is not intended to limit the scope of the present invention to this embodiment.

[0011] In the following description and drawings, the Z direction means the vertically upward direction. The longitudinal direction of the ceiling member of the vehicle orthogonal to the Z direction is referred to as the X direction.

[0012] (Configuration of the ceiling member) FIG. 1(a) is a perspective view showing a ceiling member 1 of a vehicle according to the first embodiment of the present invention. The ceiling member 1 is specifically a roof lining. FIG. 1(b) is a schematic enlarged view of part A in FIG. 1, showing a protruding portion 10 having a hole 15 and a part of a main body 21 covering the ceiling panel of the vehicle in the ceiling member 1. The protruding portion 10 and the main body 21 of the ceiling member 1 are integrally formed of a material generally used for ceiling members, such as urethane.

[0013] (Configuration of the protruding portion) In the present embodiment, the shape of the hole 15 in the protruding portion 10 is rectangular. Thereby, when the cross-sectional shape of the hook of the carrier for transporting the ceiling member 1 is rectangular, the protruding portion 10 can be stably supported by the hook. The hole 15 of the protruding portion 10 can be formed into an appropriate shape according to the shape of the hook. In the present embodiment, the protruding portion 10 is formed on one side of the peripheral edge in the longitudinal direction of the main body 21 of the ceiling member 1 of the vehicle, and the ceiling member 1 can be transported by hanging the protruding portion 10 on the hook. Thereby, it becomes easy to place the ceiling member 1 upright after transporting it to the destination. When the ceiling member 1 is placed upright, the space required for placement is smaller than when the ceiling member 1 is placed flat and arranged one by one. When the ceiling members 1 are placed flat and stacked, the lower the ceiling member 1 is placed, the more easily it is damaged by the weight of the ceiling member 1 placed above it. Such problems are also reduced in the present embodiment.

[0014] Here, in order to explain the effects of the present embodiment, a method for transporting the ceiling member of the comparative example will be described. FIG. 2 is a side view showing a state in which the main bodies 20 and 21 of the ceiling member are to be held and transported via the transporter 120 in the comparative example. The main bodies 20 and 21 of the ceiling member are transported separately, but for convenience, both are shown overlapped in FIG. 2. The main body 21 of the ceiling member is larger than the main body 20 because it is assembled to a vehicle model larger than the vehicle model to which the main body 20 of the ceiling member is assembled. The main body 20 of the ceiling member is shown by a dashed line, and the main body 21 of the ceiling member is shown by a solid line. The transporter 120 is connected to the rail 100 via the coupler 110. A portion of the coupler 110 in contact with the rail 100 can be moved along the rail 100 by a drive mechanism (not shown). By this movement, the transporter 120 is moved, and as a result, the main bodies 20 and 21 of the ceiling member held via the transporter 120 can be transported by the transporter 120.

[0015] The relatively small main body 20 of the ceiling member is provided with holes 140a and 140b for attaching assist grips to the vehicle. The holes 140a and 140b are equidistant from one side (the plus side in the Z direction) of the peripheral edge of the main body 20 of the ceiling member. For stable transportation of the main body 20 of the ceiling member, it is preferable that the holes 140a and 140b sandwich the center of gravity 25 of the main body 20 in the X direction. The hooks 130a and 130b are equal in length to each other. The lower end of the hook 130a is hung on the hole 140a, the lower end of the hook 130b is hung on the hole 140b, and the upper ends of the hooks 130a and 130b are hung on the transporter 120. In this case, neither the hook 130a nor the hook 130b is inclined with respect to the Z direction, and thereby, the main body 20 of the ceiling member can be stably suspended from the transporter 120. The positions where the hooks 130a and 130b are supported by the transporter 120 can be adjusted according to the positions of the holes 140a and 140b.

[0016] In the main body 21 of the relatively large ceiling member, holes 141a and 141b for attaching assist grips to the vehicle are provided. The holes 141a and 141b are equidistant from one side (the plus side in the Z direction) of the peripheral edge of the main body 21 of the ceiling member. In FIG. 2, the hole 140a in the main body 20 of the ceiling member coincides with the hole 141a in the main body 21 of the ceiling member. For the stable transportation of the main body 21 of the ceiling member, it is preferable that the holes 141a and 141b sandwich the center of gravity 26 of the main body 21 in the X direction. The hook 130a and the hook 130c have the same length. The lower end of the hook 130a is hung on the hole 141a, the lower end of the hook 130c is hung on the hole 141c, and the upper end of the hook 130a is hung on the transporter 120. However, there is no transporter 120 directly above the hole 141b in the vertical direction. For this reason, the upper end of the hook 130c cannot be hung on the transporter 120 without tilting the hook 130c with respect to the Z direction. Tilting at least one of the hooks 130a and 130c with respect to the Z direction will make the transportation of the main body 21 of the ceiling member unstable. In order to stably transport the main body 21 of the ceiling member in the same way as the main body 20 of the ceiling member, it is necessary to increase the dimension of the transporter 120 in the X direction so that the upper end of the hook 140c can be hung.

[0017] FIG. 3 is a side view showing a state in which the main body 21 of the ceiling member is held and transported via the transporter 120 according to the first embodiment. A protruding portion 10 is provided on the peripheral edge 150 where the holes 141a and 141b of the main body 21 of the ceiling member are provided, by integrally molding with the main body 21 of the ceiling member. The protruding portion 10 is provided so as to sandwich the center of gravity 26 between the hook 130a and the hole 141a in the X direction. The length of the hook 200 can be adjusted so that the main body 21 of the ceiling member does not tilt when the lower end is hooked on the protruding portion 10 and the upper end is hooked on the transporter 120. With this configuration, it becomes easy to transport the main body 21 of the ceiling member without tilting it. The dimensions of the protruding portion 10 are, for example, a length of 45 mm in the X direction, a length of 20 mm in the Z direction, a thickness of 4 mm, and a width of 10 mm.

[0018] (Second Embodiment) FIG. 4 is a side view showing how the main body 22 of the ceiling member according to the second embodiment is held and transported via the transporter 120. There are no holes in the main body 22 of the ceiling member into which a hook can be hooked. Two protruding portions 10a and 10b are provided integrally with the main body 22 of the ceiling member on one side of the peripheral edge portion 160 in the longitudinal direction of the main body 22 of the ceiling member. In the X direction, the protruding portion 10a and the protruding portion 10b are provided so as to sandwich the center of gravity 27. The lengths of the hooks 210a and 210b can be adjusted so that the main body 22 of the ceiling member does not tilt when the lower ends hook the protruding portions 10a and 10b and the upper ends are hooked to the transporter 120b.

[0019] From the considerations of the first and second embodiments, in order to stably transport the ceiling member without tilting, in practice, for each type of main body of the ceiling member having irregularities on the peripheral edge, protruding portions and hooks having sizes determined according to the irregularities should be prepared. This makes it easier to perform stable transportation with a transporter of a limited size even when there are no appropriate holes in the main body of the ceiling member of the vehicle into which the hook can be hooked, and when the above-mentioned appropriate holes are too far apart from each other with respect to the size of the transporter.

[0020] (Alignment of the ceiling member) The protruding portions 10a and 10b can be used for aligning the main body 22 of the ceiling member with the ceiling panel. By carrying the ceiling member into the attachment area to the ceiling panel and aligning the protruding portions 10a and 10b at the predetermined positions, the position of the main body 22 of the ceiling member can be adjusted to the desired position. For this purpose, it is preferable to previously provide marks for alignment on the ceiling panel.

[0021] (Temporary fixing of the ceiling member) FIG. 5 is a view showing how the protruding portion 10a is utilized when temporarily fixing the main body 22 of the ceiling member to the ceiling panel 240. It is assumed that the ceiling panel 240 is in a state substantially parallel to the ground. The same applies to the protruding portion 10b. FIG. 5(a) is a partial cross-sectional view of the jig 245 used for temporary fixing, as seen from the longitudinal direction of the main body 22 of the ceiling member, showing the shape of the jig 245. The jig 245 includes a U-shaped portion (U-shaped part) into which the end of the ceiling panel 240 is inserted, and a portion (insertion / fixing part) that extends from the U-shaped portion and is relatively inserted into the hole 15 of the protruding portion 10a and then fixes the protruding portion 10a.

[0022] After passing the tip of the jig 245 through the hole 15 of the protruding portion 10a, the protruding portion 10a and the main body 22 of the ceiling member are rotated counterclockwise by 90°. Then, the tip of the protruding portion 10a is inserted into a recess having the same width as the thickness of the protruding portion 10a, formed by the tip of the jig 245. As a result, the state shown in FIG. 5(b), which is a partial cross-sectional view seen from the same direction as FIG. 5(a), is obtained, and since the tip of the protruding portion 10a is fixed by the jig 245, the protruding portion 10a and the main body 22 of the ceiling member can be temporarily fixed.

[0023] Consider the case where the depth dimensions in the direction perpendicular to the paper surface of the U-shaped portion and the insertion / fixing part of the jig 245 are constant. In this case, as shown in FIG. 5(c), which is a partial view seen from vertically above the state of FIG. 5(b), the jig 245 appears as a plurality of rectangles separated by the protruding portion 10a. And as shown by the dashed line in FIG. 5(d), which is a partial view seen from vertically below the state of FIG. 5(b), a portion that is not visibly protruding is hidden by the main body 22 of the ceiling member formed in a shape that encloses the portion. This portion is a part of the connecting portion between the portion in contact with the upper surface of the ceiling panel 240 and the portion in contact with the lower surface inside the U-shaped portion, and the portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion.

[0024] In FIG. 5(b), consider the case where the depth dimensions in the direction perpendicular to the paper surface of the U-shaped portion and the insertion / fixing portion of the jig 245 are not constant. For example, consider the case where the above-mentioned dimension of the insertion / fixing portion is smaller than the above-mentioned dimension of the portion in contact with the upper surface of the ceiling panel 240 inside the U-shaped portion and larger than the above-mentioned dimension of the portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion. It is preferable for the above-mentioned dimension of the connecting portion between the portion in contact with the upper surface and the portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion to be close to the above-mentioned dimension of the hole 15 of the protruding portion 10a for the stability of the temporary fixing state. Also, the larger the above-mentioned dimension of the portion in contact with the upper surface of the ceiling panel 240 inside the U-shaped portion, the greater the effect of suppressing the movement of the portion in contact with the upper surface of the ceiling panel 240 inside the U-shaped portion rotating about the lower surface of the ceiling panel 240 as the central axis. The portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion serves to suppress the movement of the insertion / fixing portion rotating in the vertically downward direction about the connection point with the U-shaped portion as the central axis. For this reason, for the portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion, the above-mentioned depth dimension may be small. The portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion may be rod-shaped.

[0025] In this case, as shown in FIG. 6(a), which is a partial view of FIG. 5(b) seen from vertically above, the jig 245 appears to be composed of three rectangles with equal widths in the X direction separated by the protruding portion 10a and one rectangle with a wide width in the X direction. And, as shown in FIG. 6(b), which is a partial view of FIG. 5(b) seen from vertically below, the jig 245 appears to be a rectangle with a wide width in the X direction with one side in contact with the main body 240 of the ceiling member, and two rectangles with equal widths in the X direction. Further, as shown by the dotted line in FIG. 6(b), there are a part of the connecting portion between the portion in contact with the upper surface and the portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion, and a rod-shaped portion in contact with the lower surface of the ceiling panel 240 inside the U-shaped portion. However, they are hidden in the main body 22 of the ceiling member formed in a shape that encloses these two portions and thus do not visibly appear.

[0026] (Processing of the protruding portion) After transporting the main body of the ceiling member, assemble it to the vehicle while leaving the protruding portions 10a and 10b. When the vehicle is completed, it is assumed that it may interfere with the inflation of the airbag. Therefore, it is preferable to appropriately cut and remove the protruding portions 10a and 10b. It is suitable to cut at the base of the protruding portions 10a and 10b with respect to the main body of the ceiling member (portion B in Fig. 1(b)) because the protruding portions 10a and 10b can be completely removed.

[0027] (Modification Example 1) Fig. 7 shows a method of forming the protruding portion 10c according to the first modification example. Fig. 7(a) is a partial side view showing the case where the main body 22 of the ceiling member is placed flat before being transported to the mounting area. The protruding portion 10c can be integrally formed at an arbitrary angle with the peripheral edge of the main body 22 of the ceiling member. As shown in the figure, when formed at an angle such that the hook 210c can easily be hooked, it becomes easier to lift the main body 22 of the ceiling member from the flat state.

[0028] Fig. 7(b) is a partial side view showing the case where the main body 22 of the ceiling member is placed vertically before being transported to the mounting area. As shown in the figure, when the protruding portion 10d is formed at an angle such that the hook 210d can easily be hooked, it becomes easier to lift the main body 22 of the ceiling member from the vertical state.

[0029] (Modification Example 2) Fig. 8 shows the state of processing the protruding portion 10a according to the second modification example. Fig. 8(a) shows the state where the ceiling panel 240, the cushioning material 300, the protruding portion 10a, and the main body 22 of the ceiling member are laminated. From this state, the protruding portion 10a may be bent without cutting until the influence of the protruding portion 10a on the design of the vehicle and functions such as the airbag is within an acceptable range. A recess 302 is provided on the side of the main body 22 of the ceiling member at the peripheral edge of the cushioning material 300. The protruding portion 10a is provided with a curved portion 305 to facilitate bending. The curved portion 305 may not be provided. Apply an external force to bend the protruding portion 10a and push it into the recess 302 of the cushioning material 300.

[0030] Figures 8(b) to (d) show an example of the bending process. As shown in Figure 8(b), by applying an external force in the direction indicated by the arrow to the protruding portion 10a, the tip side of the protruding portion 10a beyond the curved portion 305 is bent from the broken line state to the solid line state facing the central portion of the ceiling member body 22. The protruding portion 10a is in a folded state. Next, as shown in Figure 8(c), by applying an external force in the direction indicated by the arrow to the protruding portion 10a, the tip of the protruding portion 10a is directed towards the recess 302 of the buffer member 300. Next, as shown in Figure 8(d), by applying an external force in the direction indicated by the arrow to the protruding portion 10a, the tip of the protruding portion 10a is pushed into the recess 302 of the buffer member 300.

[0031] Figures 8(e) to (g) show another example of the bending process. As shown in Figure 8(e), by applying an external force in the direction indicated by the arrow to the protruding portion 10a, the tip side of the protruding portion 10a beyond the curved portion 305 is bent from the broken line state to the solid line state. The protruding portion 10a bends, but does not bend as much as shown in Figure 8(b). As shown in Figure 8(f), by applying an external force in the direction indicated by the arrow to the protruding portion 10a, the tip of the protruding portion 10a is directed towards the recess 302 of the buffer member 300. The length of the straight portion of the protruding portion 10a facing the recess 302 of the buffer member 300 becomes shorter than that shown in Figure 8(c). As shown in Figure 8(g), by applying an external force in the direction indicated by the arrow to the protruding portion 10a, the tip of the protruding portion 10a is pushed into the recess 302 of the buffer member 300. Although only the straight portion of the protruding portion 10a facing the recess 302 of the buffer member 300 being pushed into the recess 302 of the buffer member 300 is illustrated, an external force may be further applied as appropriate to push it deeper into the recess 302 of the buffer member 300.

[0032] Since the external force application mode in the process of Fig. 8(f) is simpler than that in the process of Fig. 8(c), in the processes shown in Figs. 8(e) to 8(g), the protruding portion 10a can be bent more simply and pushed into the recess 302 of the buffer member 300. According to the length of the protruding portion 10a to be pushed into the recess 302 of the buffer member 300 and the like, the processes shown in Figs. 8(b) to 8(d) and Figs. 8(e) to 8(g) and other bending methods can be appropriately selected to bend the protruding portion 10a.

[0033] In the processes shown in Figs. 8(b) to 8(d) and Figs. 8(e) to 8(g), the recess 302 of the buffer member 300 has a tapered shape in which the height decreases toward the peripheral edge of the main body 22 of the ceiling member. Thereby, after the bent protruding portion 10a is pushed into the recess 302 of the buffer member 300, it becomes easier to prevent the protruding portion 10a from returning to its original shape due to the restoring force at the entrance of the recess 302. The recess 302 does not necessarily have to be tapered, and the height of the recess 302 may be constant. Also, the recess 302 may have a tapered shape in which the height increases toward the peripheral edge of the main body 22 of the ceiling member. In this case, it becomes easier to push the bent protruding portion 10a into the recess 302 of the buffer member 300, and it also becomes easier to hold the protruding portion 10a at the inner part of the recess 302.

Explanation of Reference Numerals

[0034] 1 Ceiling member 10, 10a, 10b Protruding portion 20, 21, 22 Main body 240 Ceiling panel

Claims

1. A ceiling member for a vehicle, comprising: a main body that covers a ceiling panel of the vehicle; and a protruding portion that is integrated with the main body and has a hole. The ceiling member.

2. The ceiling member according to claim 1, wherein the protruding portion is at a peripheral edge of the main body.

3. The ceiling member according to claim 1 or 2, wherein the protruding portion is bendable from a peripheral edge of the main body toward a central portion of the main body.

4. A method for manufacturing a ceiling member for a vehicle, comprising: a step of integrally molding a main body that covers a ceiling panel of the vehicle and a protruding portion having a hole. The method for manufacturing the ceiling member.

5. The method for manufacturing a ceiling member according to claim 4, wherein the protruding portion is at a peripheral edge of the ceiling member.

6. A method for installing a ceiling member for a vehicle, comprising: a step of integrally molding a main body that covers a ceiling panel of the vehicle and a protruding portion having a hole to manufacture the ceiling member; a step of transporting the ceiling member using the hole; a step of attaching the ceiling member to the ceiling panel of the vehicle; and a step of cutting the protruding portion. The method for installing the ceiling member.

7. A method for installing a ceiling member for a vehicle, comprising: a step of integrally molding a main body that covers a ceiling panel of the vehicle and a protruding portion having a hole to manufacture the ceiling member; a step of transporting the ceiling member using the hole; a step of attaching the ceiling member to the ceiling panel of the vehicle; and a step of bending the protruding portion toward a central portion of the main body and supporting the protruding portion in a recess formed between the ceiling panel and the main body. The method for installing the ceiling member.

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