Vehicle roof

Abstract

To provide a vehicular roof which secures rust resistance.SOLUTION: A vehicular roof 100 includes: a resin covered steel plate 10 including a steel plate 11 and a first resin layer 12 covering a passenger compartment side surface of the steel plate 11; and a vibration suppression material provided on the passenger compartment side surface of the resin covered steel plate 10. The resin covered steel plate 10 includes a thin layer area 10a in which a thickness of a coated film formed by electrodeposition coating is smaller than that of a periphery 10b when electrodeposition coating is performed on the steel plate 11. The vibration suppression material 20 is provided at the thin layer area 10a on the passenger compartment side surface of the resin covered steel plate 10.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a vehicle roof, and more particularly to a vehicle roof using a resin-coated steel sheet. [Background technology]

[0002] Patent Document 1 discloses that a resin-coated steel sheet, the surface of which is covered with a resin layer and has anti-rust properties, is used in a vehicle. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2015-202686 A Summary of the Invention [Problem to be solved by the invention]

[0004] The present inventors have discovered the following problems. Since resin-coated steel sheets are more expensive than normal steel sheets, it is necessary to appropriately select the parts of the vehicle where they are used. Meanwhile, a vehicle body having a roof steel sheet can be manufactured with an anti-rust painted roof by submerging the vehicle body having a roof steel sheet in a coating liquid and applying electrodeposition coating. During electrodeposition coating, air pockets may be generated on the passenger compartment side surface of the roof steel sheet, resulting in a thin coating film formed by electrodeposition coating. Therefore, anti-rust properties cannot be ensured, and vibration-damping materials cannot be provided in areas where the coating film formed by electrodeposition coating is thin.

[0005] In view of the above-mentioned problems, an object of the present invention is to provide a vehicle roof that ensures rust resistance. [Means for solving the problem]

[0006] A vehicle roof according to one aspect of the present invention includes: A roof for a vehicle, comprising: A resin-coated steel plate including a steel plate and a first resin layer that coats a cabin-side surface of the steel plate; a vibration-damping material provided on a cabin-side surface of the resin-coated steel plate, The resin-coated steel sheet includes a thin-layer region in which the coating film formed by the electrodeposition coating is thinner than the surrounding area when the steel sheet is electrodeposition-coated, The vibration-damping material is provided in the thin layer region on the passenger compartment side surface of the resin-coated steel plate.

[0007] According to this configuration, the resin layer covers the thin layer region on the vehicle interior side surface of the vehicle roof, ensuring rust resistance of the thin layer region. Therefore, the vibration-damping material can be provided in the thin layer region on the vehicle interior side surface of the vehicle roof.

[0008] The vehicle further includes a frame provided on the vehicle interior side surface of the resin-coated steel plate, the frame is covered with a second resin layer; The first resin layer may be thicker than the second resin layer.

[0009] According to this configuration, the first resin layer covers the cabin side surface of the steel plate and is thicker than the second resin layer. This improves the rust resistance of the cabin side surface of the steel plate. Furthermore, the second resin layer is thinner than the first resin layer. This reduces the amount of resin layer used in the frame, thereby reducing costs.

[0010] The vehicle further includes a frame provided on the vehicle interior side surface of the resin-coated steel plate, The frame may be characterized in that it is not covered with a resin layer.

[0011] According to such a configuration, since the frame is not covered with a resin layer, the amount of resin layer used in the frame is zero, which allows further cost reduction.

[0012] The resin-coated steel sheet further includes a third resin layer covering the vehicle outer surface of the front steel sheet, The first resin layer may be thicker than the third resin layer.

[0013] According to this configuration, the first resin layer is thicker than the third resin layer, and therefore enhances the rust prevention of the vehicle interior side surface of the steel plate. Also, the third resin layer covers the vehicle outer surface of the steel plate, and enhances the rust prevention of the vehicle outer surface of the steel plate. Also, the third resin layer is thinner than the first resin layer, and therefore the amount of resin layer used on the vehicle outer surface of the steel plate can be reduced, and costs can be reduced.

[0014] The vehicle outer surface of the front steel plate may be characterized in that it is not covered with a resin layer.

[0015] According to this configuration, since the vehicle outer surface of the steel plate is not covered with a resin layer, the amount of resin layer used on the vehicle outer surface of the steel plate is zero, enabling further cost reduction. Effect of the Invention

[0016] According to the present invention, it is possible to provide a vehicle roof that ensures rust resistance. [Brief description of the drawings]

[0017] [Figure 1] FIG. 2 is a bottom view showing an example of a vehicle roof according to the first embodiment. [Diagram 2] 1 is a cross-sectional view of a main portion of an example of a vehicle roof according to a first embodiment. [Diagram 3] 2 is a cross-sectional view of a main portion of one specific example of a vehicle roof according to the first embodiment. FIG. [Figure 4] FIG. 4 is a bottom view showing a first modified example of the vehicle roof according to the first embodiment. [Diagram 5] 4 is a cross-sectional view of a main portion of a first modified example of the vehicle roof according to the first embodiment. FIG. [Figure 6] 6 is a cross-sectional view of a main portion of a second modified example of the vehicle roof according to the first embodiment. FIG. [Figure 7]13 is a cross-sectional view of a main portion of a third modified example of the vehicle roof according to the first embodiment. FIG. [Figure 8] FIG. 1 is a cross-sectional view showing an example of a vehicle roof according to a related art. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] (Related Technology) Prior to the description of the embodiment, a vehicle roof 900 according to the related art will be described. In the vehicle roof 900 shown in FIG. 8, a vibration-damping material 920 is pressure-bonded to the cabin-side surface of a steel plate 810 via a coating film 811. The coating film 811 is formed on the cabin-side surface of the steel plate 810 by electrochemical coating. However, due to the difficulty of attaching the vibration-damping material 920 facing upwards, the vibration-damping material 920 is not completely pressure-bonded to the cabin-side surface of the steel plate 810 via the coating film 811, and an end 920a of the vibration-damping material 920 may peel off from the coating film 811. In such a case, the condensed water W1b travels along the cabin-side surface of the steel plate 810 and reaches the end 920a of the vibration-damping material 920. Then, the condensed water W1b is held between the end 920a of the vibration-damping material 920 and the steel plate 810. This makes it easier for rust to progress, and rust prevention may not be ensured.

[0019] Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. In addition, the following description and drawings are appropriately simplified for clarity of explanation.

[0020] (Embodiment 1) A first embodiment will be described with reference to Figs. 1 to 3. Fig. 1 is a bottom view showing an example of a vehicle roof according to the first embodiment. Fig. 2 is a cross-sectional view showing a cross-section of a main part of the example of the vehicle roof shown in Fig. 1. Fig. 3 is a cross-sectional view showing a cross-section of a main part of the example of the vehicle roof shown in Fig. 1.

[0021] Naturally, the right-handed xyz coordinate system shown in FIG. 1 and other drawings is for the convenience of explaining the positional relationship of the components. Usually, the positive z-axis direction (UPR) is vertically upward and toward the outside of the vehicle cabin, and the negative z-axis direction (DWN) is vertically downward and toward the inside of the vehicle cabin. The negative x-axis direction (FR) is the front of the vehicle cabin, and the positive x-axis direction (RR) is the rear of the vehicle cabin. The negative y-axis direction (LT) is the leftward direction of the vehicle cabin, and the positive y-axis direction (RT) is the rightward direction of the vehicle cabin. The xy plane is a horizontal plane, and is common to all drawings.

[0022] As shown in FIG. 1, a vehicle roof 100 includes a resin-coated steel plate 10 and a vibration-damping material 20 .

[0023] The resin-coated steel sheet 10 comprises a steel sheet 11 and a first resin layer 12 .

[0024] The steel sheet 11 has a vehicle roof shape. The vehicle roof shape may be, for example, a shape in which the entire area or a part of the area protrudes outside the vehicle cabin, or a shape similar to a pagoda roof. An example of a pagoda roof is a shape in which the center protrudes inside the vehicle cabin and both ends protrude outside the vehicle cabin when viewed from the front of the vehicle. The steel sheet 11 has mechanical properties required for a vehicle roof. Specifically, the steel sheet 11 may be made of ordinary steel or steel containing an additive element such as chromium. A plating film may be provided on the surface of the steel sheet 11. The type of the plating film on the surface of the steel sheet 11 is not particularly limited. Applicable plating films include, for example, plating containing any one of zinc, aluminum, cobalt, tin, and nickel, and alloy plating containing these metal elements, other metal elements, and nonmetal elements. Depending on the application, both sides, only one side, a part of the surface, or the entire surface of the metal sheet may be covered with a coating film.

[0025] The resin-coated steel sheet 10 includes a thin layer region 10a. When the steel sheet 11 is electrocoated, the thin layer region 10a is a region where the thickness of the coating film by electrocoating is thinner than the periphery 10b. The thickness of the thin layer region 10a may change continuously. For example, the thickness of the thin layer region 10a may change continuously so as to become gradually thinner from the boundary between the thin layer region 10a and the periphery 10b toward the center of the thin layer region 10a. The thin layer region 10a may be empirically determined by electrocoating the steel sheet 11. Specifically, when the thin layer region 10a is electrocoated, the thin layer region 10a is a region where an air pocket where air has accumulated is generated on the cabin side surface of the steel sheet 11. More specifically, as shown in FIG. 3, the thin layer region 10a is a convex region that protrudes toward the outside of the cabin from the periphery 10b.

[0026] As shown in FIG. 2, the first resin layer 12 covers the cabin side surface of the steel sheet 11. The first resin layer 12 contains a resin and has a higher rust prevention property than the steel sheet 11. As a result, the first resin layer 12 enhances the rust prevention property of the steel sheet 11. Such a resin is, for example, an organic resin such as a water-based coating composition or an organic solvent-based coating composition. In order to further improve the adhesion of the first resin layer 12 to the steel sheet 11 and the corrosion resistance, etc., a base treatment film may be provided between the first resin layer 12 and the surface of the steel sheet 11. When a base treatment film is provided in this way, the number and composition of the layers of the base treatment film are not limited. The first resin layer 12 may further contain a pigment. Such a pigment is, for example, an anti-rust pigment or a conductive pigment. The type of the anti-rust pigment and the type of the conductive pigment are not particularly limited, but it is preferable that the anti-rust pigment contains at least one selected from, for example, a silicate compound, a phosphate compound, a vanadate compound, and metal oxide fine particles. The conductive pigment preferably contains at least one material selected from the group consisting of metals, alloys, conductive carbon, iron phosphide, carbides, and semiconductor oxides.

[0027] The resin-coated steel sheet 10 may include at least one of an electrodeposition coating layer, an intermediate coating layer, and a topcoat coating layer. At least one of the electrodeposition coating layer, the intermediate coating layer, and the topcoat coating layer covers at least a part of the first resin layer 12.

[0028] The vibration-damping material 20 is provided in the thin layer region 10a on the cabin-side surface of the steel plate 11. The vibration-damping material 20 may cover the entire thin layer region 10a or may cover a part of the thin layer region 10a. The vibration-damping material 20 may be any material that suppresses vibration or noise.

[0029] As described above, according to the configuration of the vehicle roof 100, the first resin layer 12 covers the thin layer region 10a on the vehicle interior side surface of the vehicle roof 100, and ensures the rust resistance of the thin layer region 10a. Therefore, the vibration-damping material 20 can be provided in the thin layer region 10a on the vehicle interior side surface of the vehicle roof 100.

[0030] Also, as with the vehicle roof 900 shown in FIG. 8, the vibration-damping material 20 may not be completely pressed against the cabin-side surface of the steel plate 11 due to the difficulty of attaching the material upward, and the end 20a of the vibration-damping material 20 may peel off from the steel plate 11. Even in such a case, the condensed water travels along the cabin-side surface of the steel plate 11 and reaches the end 20a of the vibration-damping material 20. Then, the condensed water is held between the end 20a of the vibration-damping material 20 and the steel plate 11. However, according to the configuration of the vehicle roof 100, the first resin layer 12 covers the thin layer region 10a on the cabin-side surface of the vehicle roof 100, thereby protecting the steel plate 11 from moisture. Therefore, even if the end 20a peels off due to the difficulty of attaching the vibration-damping material 20, the rust-proofing of the thin layer region 10a can be ensured.

[0031] Next, an example of a method for manufacturing the vehicle roof 100 will be described. First, a coating film is applied onto the vehicle inner surface of the steel plate 11 to form the first resin layer 12 on the steel plate 11. Next, the steel plate 11 on which the first resin layer 12 has been formed is processed or shaped into the shape of the vehicle roof 100. Furthermore, the vibration-damping material 20 is provided in the thin layer region 10a on the passenger compartment side surface of the processed or shaped steel plate 11. In this manner, the vehicle roof 100 can be manufactured. If necessary, at least one of electrocoating, intermediate coating, and top coating may be applied to the processed or shaped steel plate 11.

[0032] (First Modification) The vehicle roof 100a shown in Figures 4 and 5 is a modified example of the vehicle roof 100 shown in Figure 1. Figure 4 is a bottom view showing a first modified example of the vehicle roof 100 shown in Figure 1. Figure 5 is a cross-sectional view of a main part of the first modified example shown in Figure 4. The vehicle roof 100a has the same configuration as the vehicle roof 100, except for the frame 30.

[0033] As shown in Fig. 4, the vehicle roof 100a includes a frame 30. The frame 30 is provided on the passenger compartment side surface of the resin-coated steel plate 10 via a vibration-damping material 20. The frame 30 reinforces the resin-coated steel plate 10. The shape of the frame 30 is not particularly limited, but may be of a wide variety of shapes. An example of the frame 30 shown in Fig. 4 is a member extending in a generally ladder shape.

[0034] As shown in Fig. 5, the frame 30 includes a frame main body 31 and a second resin layer 32. The frame main body 31 has mechanical strength necessary to reinforce the resin-coated steel plate 10. The second resin layer 32 covers the frame main body 31. Specifically, the second resin layer 32 covers at least the surface of the frame main body 31 facing the resin-coated steel plate 10. The second resin layer 32 contains resin, similar to the first resin layer 12, and has higher rust resistance than the steel plate 11.

[0035] The first resin layer 12 is thicker than the second resin layer 32. In other words, the thickness t12 of the first resin layer 12 is greater than the thickness t31 of the second resin layer 32.

[0036] As described above, according to the configuration of the vehicle roof 100a, the first resin layer 12 covers the interior side surface of the steel plate 11 and is thicker than the second resin layer 32. Therefore, the rust resistance of the interior side surface of the steel plate 11 is improved. Furthermore, since the second resin layer 32 is thinner than the first resin layer 12, the amount of resin layer used in the frame 30 can be suppressed, and costs can be reduced. Since the second resin layer 32 covers the frame main body 31, the rust resistance of the frame 30 can be ensured.

[0037] (Second Modification) The vehicle roof 100b shown in Fig. 6 is a modified example of the vehicle roof 100 shown in Fig. 1. Fig. 6 is a cross-sectional view showing a cross-section of a main part of a second modified example of the vehicle roof 100 shown in Fig. 1. The vehicle roof 100b has the same configuration as the vehicle roof 100, except for the frame 30a.

[0038] As shown in Fig. 6, the vehicle roof 100b includes a frame 30a. The frame 30a has the same configuration as the frame 30 except that it does not include the second resin layer 32. The frame 30a includes a frame main body 31. The frame main body 31 is not covered with a resin layer. Note that the vehicle roof 100a shown in Fig. 5 has the same configuration as the vehicle roof 100b when the thickness t31 of the second resin layer 32 is 0 (zero).

[0039] As described above, according to the configuration of the vehicle roof 100b, since the frame 30a is not covered with a resin layer, the amount of resin layer used in the frame 30a is 0 (zero), which allows further cost reduction.

[0040] (Third Modification) The vehicle roof 100c shown in Fig. 7 is a modified example of the vehicle roof 100 shown in Fig. 1. Fig. 7 is a cross-sectional view showing a cross-section of a main part of a third modified example of the vehicle roof 100 shown in Fig. 1. The vehicle roof 100c has the same configuration as the vehicle roof 100, except for the third resin layer 13.

[0041] 7, the vehicle roof 100c includes a third resin layer 13, and the third resin layer 13 covers at least a part of the vehicle outer surface of the steel plate 11. The third resin layer 13 contains a resin like the first resin layer 12, and has higher rust resistance than the steel plate 11.

[0042] The first resin layer 12 is thicker than the third resin layer 13. In other words, the thickness t12 of the first resin layer 12 is greater than the thickness t13 of the third resin layer 13.

[0043] As described above, according to the configuration of the vehicle roof 100c, the first resin layer 12 covers the passenger compartment side surface of the steel plate 11 and is thicker than the third resin layer 13. Therefore, the rust prevention of the passenger compartment side surface of the steel plate 11 is improved. Furthermore, since the third resin layer 13 covers at least a part of the vehicle outer surface of the steel plate 11, the rust prevention of the vehicle outer surface of the steel plate 11 can be ensured. Since the third resin layer 13 is thinner than the first resin layer 12, the amount of resin layer used on the vehicle outer surface of the steel plate 11 can be suppressed, thereby reducing costs.

[0044] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the present invention. In addition, the present invention can be implemented by appropriately combining the above-described embodiment and examples thereof. [Explanation of symbols]

[0045] 100, 100a, 100b, 100c Vehicle roof 10 Resin-coated steel sheet 10a Thin layer area 10b Surroundings 11 steel plate 12 first resin layer 13 Third resin layer 20 Damping material 30, 30a frames 31 Frame body 32 Second resin layer t12: thickness of the first resin layer 12; t31: thickness of the second resin layer 32; t13: Thickness of the third resin layer 13

Claims

1. A roof for a vehicle, comprising: A resin-coated steel plate including a steel plate and a first resin layer that coats a cabin-side surface of the steel plate; a vibration-damping material provided on a cabin-side surface of the resin-coated steel plate, The resin-coated steel sheet includes a thin-layer region in which the coating film formed by the electrodeposition coating is thinner than the surrounding area when the steel sheet is electrodeposition-coated, The vibration-damping material is provided in the thin layer region of the vehicle cabin side surface of the resin-coated steel plate. Roof for vehicle.

2. The resin-coated steel plate further includes a frame provided on the cabin side surface thereof, the frame is covered with a second resin layer, The first resin layer is thicker than the second resin layer.

2. The vehicle roof according to claim 1.

3. The resin-coated steel plate further includes a frame provided on the cabin side surface thereof, The frame is not covered with a resin layer.

2. The vehicle roof according to claim 1.

4. The resin-coated steel sheet further includes a third resin layer covering the vehicle outer surface of the front steel sheet, The first resin layer is thicker than the third resin layer.

4. The vehicle roof according to claim 1, wherein the roof is made of a plastic material.

5. The outer surface of the front steel plate is not covered with a resin layer.

4. The vehicle roof according to claim 1, wherein the roof is made of a plastic material.

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