Ceiling Panel

Abstract

To develop a ceiling panel which is suitable for air flowing between a roof panel and the ceiling panel.SOLUTION: A ceiling panel is overlapped with a roof panel of a vehicle from below to form an air passage with the roof panel. The ceiling panel includes projections, each of which extends in a vehicle fore and aft direction and is formed by a first foam resin enabling at least an upper part to be elastically deformed, on its upper surface.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a ceiling panel that is laminated from below onto a roof panel of a vehicle. [Background technology]

[0002] There is known a technique for allowing air to flow between a roof panel and a ceiling panel (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2000-142089 (Fig. 1, etc.) Summary of the Invention [Problem to be solved by the invention]

[0004] There is a need to develop a ceiling panel that is suitable for allowing air to flow between the roof panel and the ceiling panel. [Means for solving the problem]

[0005] A first aspect of the invention made to solve the above problem is a ceiling panel that is placed on top of a vehicle roof panel from below and forms an air flow path between the roof panel and the roof panel, the ceiling panel extending in the fore-and-aft direction of the vehicle and having a protrusion on its upper surface, at least the upper part of which is formed from a first foamed resin that is elastically deformable. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a side view of a ceiling panel that is attached to a vehicle and forms an air flow path between the ceiling panel and the roof panel. [Diagram 2] Back cross section of ceiling panel [Diagram 3] FIG. 1 is an exploded perspective view of a roof structure of a vehicle; [Figure 4] Plan view of ceiling panel [Diagram 5](A) A cross-sectional side view of the area around the compressed portion of the protrusion before compression, (B) A cross-sectional side view of the compressed portion compressed against the cross beam when the ceiling panel is fixed to the vehicle. [Figure 6] FIG. 13 is a side cross-sectional view of the periphery of a compressed portion of a protrusion of a ceiling panel according to another embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] [First embodiment] As shown in Fig. 1, a ceiling panel 10 of the first embodiment is attached to a roof panel 91 of a vehicle 90. As shown in Fig. 2, the ceiling panel 10 is an interior material that is placed on the roof panel 91 from below, and constitutes the ceiling of the passenger compartment of the vehicle 90. As shown in Fig. 3, a reinforcement 80 is disposed between the ceiling panel 10 and the roof panel 91. The reinforcement 80 is applied to and fixed to the roof panel 91, and reinforces the roof panel 91.

[0008] For example, the reinforcement 80 is provided with a pair of side rail reinforcements 80S that are overlapped on the sides of the roof panel 91, and is also provided with a number of cross beams 81 that span the side rail reinforcements 80S and extend in the vehicle width direction (left-right direction). The cross beams 81 are attached to the underside of the roof panel 91 (see FIG. 2). As shown in FIG. 3, the front and rear ends of the side rail reinforcement 80S are connected to the A-pillar reinforcement 80A and the C-pillar reinforcement 80C, respectively, and a B-pillar reinforcement 80B extends downward from a midpoint of the side rail reinforcement 80S.

[0009] As shown in Fig. 2, an air flow path R is formed between the roof panel 91 and the ceiling panel 10. The flow path R is configured to allow air to pass between the roof panel 91 and the ceiling panel 10 in the front-rear direction of the vehicle 90 (see Fig. 4).

[0010] As shown in Figures 3 and 4, in this embodiment, air is supplied from the front to the flow path R by a supply duct 30. The supply duct 30 supplies air from an air conditioner 36 (see Figure 1) provided, for example, at the front of the vehicle 90. The air conditioner 36 takes in air outside the vehicle 90 and supplies it to the supply duct 30. Note that the air conditioner 36 may not be provided and air taken in from outside the vehicle 90 may be supplied to the supply duct 30. Also, air inside the vehicle 90 may be supplied to the supply duct 30 by the air conditioner 36.

[0011] The rear end of the flow path R (i.e., the rear end of the ceiling panel 10) is connected to, for example, an exhaust duct 37 (see FIG. 1). The air that has passed through the flow path R from the front side to the rear side is exhausted by the exhaust duct 37, for example, to the outside of the vehicle 90.

[0012] In this way, it is possible to improve the thermal insulation between the roof panel 91 and the vehicle interior by allowing air to flow between the roof panel 91 and the ceiling panel 10. For example, it is possible to make it difficult for heat of the roof panel 91 caused by direct sunlight in summer to be transmitted to the vehicle interior.

[0013] As shown in Figs. 1 and 3, in this embodiment, the supply duct 30 is disposed along the A-pillar of the vehicle 90 inside the vehicle 90. In this embodiment, a pair of supply ducts 30 are provided on the left and right sides of the vehicle 90. Specifically, the supply duct 30 extends rearward from the air conditioning device 36 (see Fig. 1) and extends along the A-pillar to above the front end of the ceiling panel 10 (see Fig. 3). The supply duct 30 is bent at a bent portion 33 and extends to above the center of the front end of the ceiling panel 10 in the vehicle width direction, and blows air rearward from a terminal blowing port 31 provided at the end of the supply duct 30 toward the flow path R. For example, as shown in Fig. 4, a midway blowing port 32 for blowing air rearward toward the flow path R may be provided between the bent portion 33 and the terminal blowing port 31 of the supply duct 30.

[0014] As shown in FIG. 2 and FIG. 3, the upper surface of the ceiling panel 10 is provided with a protrusion 20. The protrusion 20 extends in the front-rear direction. In this embodiment, the protrusion 20 has a protruding height that abuts against the roof panel 91. The protrusion 20 divides the flow path R in the vehicle width direction of the vehicle 90, thereby forming a plurality of partitioned flow paths R1 through which air flows. When viewed from above, the protrusion 20 and the partitioned flow path R1 extend straight in the front-rear direction (see FIG. 4). In detail, the upper end of the protrusion 20 abuts against the roof panel 91 or a reinforcement 80 (e.g., a cross beam 81) on the lower surface of the roof panel 91. In addition, it is preferable that the terminal outlet 31 and the intermediate outlet 32 ​​in the supply duct 30 are provided corresponding to each partitioned flow path R1.

[0015] 2 and 4, in this embodiment, a plurality of ribs 20 are provided at intervals in the vehicle width direction. These ribs 20 are, for example, linear and substantially parallel to each other when viewed from above. These ribs 20 may be, for example, disposed at substantially equal intervals. It is also possible to provide only one rib 20.

[0016] As shown in Fig. 2, in this embodiment, the protrusions 20 are fixed to the upper surface of the panel body 11 that constitutes the ceiling surface of the vehicle compartment, and protrude from the panel body 11. The panel body 11 is obtained, for example, by press molding a sheet material. The panel body 11 has, for example, a generally rectangular shape in a plan view (see Fig. 4), with the central portion gently bulging upward in correspondence with the shape of the roof panel 91 (see Fig. 3). In this embodiment, the protrusions 20 are bonded to the panel body 11.

[0017] At least the upper portion of the rib 20 is made of an elastically deformable foamed resin (hereinafter referred to as a first foamed resin). In this embodiment, the rib 20 has a laminated structure in which a plurality of layers are stacked in the vertical direction, and the uppermost layer is a first foamed resin layer 21 made of the first foamed resin. Under the first foamed resin layer 21, a second foamed resin layer 22 made of a second foamed resin having a higher hardness than the first foamed resin is provided. Specifically, in this embodiment, the rib 20 has a two-layer structure made of the first foamed resin layer 21 and the second foamed resin layer 22. Therefore, the entire rib 20 is elastically deformable.

[0018] In this embodiment, the first foamed resin is a soft foamed resin. For example, both side portions 21S (portions facing the flow path R shown in FIG. 2) of the first foamed resin layer 21 of the protrusion 20, which is made of the first foamed resin, have at least an open-cell structure. This makes it possible to absorb sound in the flow path R. The first foamed resin layer 21 may have an open-cell structure as a whole. For example, the first foamed resin may be soft polyurethane foam, but is not limited thereto. The first foamed resin layer 21 may have a closed-cell structure.

[0019] In this embodiment, the second foamed resin is a hard foamed resin. Examples of the second foamed resin include, but are not limited to, foamed polypropylene, foamed polyethylene, and hard foamed polyurethane. The second foamed resin layer 22 may have a closed cell structure or an open cell structure.

[0020] The hardness of the foamed resin can be measured, for example, by the D method defined in JIS K6400-2 6.7. The hardness of the first foamed resin according to the JIS K6400-2 D method is preferably 250 N or less. If the first foamed resin has such hardness, it becomes possible to make the protrusions 20 easily conform to the unevenness on the roof panel 91 side.

[0021] 2, in this embodiment, the ridges 20 are in the shape of square bars having a cross section in a quadrangular shape (e.g., rectangular shape). The ridges 20 may be formed by cutting a sheet material (e.g., a sheet material having a laminated structure) into thin strips approximately parallel to each other.

[0022] Here, as shown in FIG. 2, since the reinforcement 80 protrudes below the roof panel 91, the portion of the protrusion 20 that abuts against the reinforcement 80 is particularly compressed. In the example of this embodiment, when the ceiling panel 10 is attached to the roof panel 91, the protrusion 20 abuts against a cross beam 81 of the reinforcement 80. As shown in FIGS. 5(A) and 5(B), when the protrusion 20 abuts against the cross beam 81, a compressed portion 26 provided at a part of the longitudinal direction of the protrusion 20 is pressed from above by the cross beam 81 and is compressed and deformed. This compressed portion 26 is a portion of the protrusion 20 that is located at a position corresponding to the cross beam 81, and in the example of this embodiment, it is provided at multiple locations in the longitudinal direction (front-rear direction) of the protrusion 20 corresponding to the multiple cross beams 81 provided.

[0023] It is preferable that the lower end of the first foamed resin layer 21 (the boundary between the first foamed resin layer 21 and the second foamed resin layer 22) is disposed below the lower surface of the cross beam 81. This makes it possible to compress the protrusion 20 by the thickness of the cross beam 81 in the vertical direction by deformation of the first foamed resin layer 21, even if the second foamed resin layer 22 is difficult to deform.

[0024] As shown in FIG. 5(A), a cut 27 is formed across the rib 20 at the front and rear of the compressed portion 26 of the rib 20. The depth of the cut 27 may be to the middle of the rib 20 in the up-down direction, or may be to the lower end of the rib 20 (i.e., the cut 27 may divide the rib 20 into front and rear parts). In this embodiment, the cut 27 is to the boundary between the first foamed resin layer 21 and the second foamed resin layer 22, and divides the first foamed resin layer 21. For example, the cut 27 may be to the middle of the first foamed resin layer 21, or may be to the middle of the second foamed resin layer 22.

[0025] In this embodiment, the distance between the pair of notches 27 sandwiching the compressed portion 26 from the front to the rear is the same as or greater than the front-to-rear width of the cross beam 81. As shown in Fig. 5(B) , when the ceiling panel 10 is attached to the roof panel 91 and the protrusion 20 is compressed by the cross beam 81, the formation of the pair of notches 27 makes it easier to locally compress the portion of the protrusion 20 sandwiched between the pair of notches 27. Note that in this embodiment, the entire portion between the pair of notches 27 forms the compressed portion 26 that is compressed by the cross beam 81.

[0026] As described above, when the ceiling panel 10 is fixed to the roof panel 91 and the air conditioning device 36 of the vehicle 90 is operated, air is supplied to the flow path R through the supply duct 30. As shown in Figs. 3 and 4, in this embodiment, a plurality of ribs 20 are provided, and air is supplied from the terminal outlet 31 and the intermediate outlet 32 ​​of the supply duct 30 to partitioned flow paths R1 of the flow path R partitioned by the ribs 20. Then, this air passes through the flow path R from the front side to the rear side, and flows out into the exhaust duct 37.

[0027] In the ceiling panel 10 of this embodiment, the ribs 20 extending in the front-rear direction make it possible to straighten the air that has flowed between the roof panel 91 and the ceiling panel 10. By straightening the air in the flow path R, it becomes possible to make the air in the flow path R flow more easily in the front-rear direction. In this way, the ceiling panel 10 has a configuration suitable for air to flow between the roof panel 91 and the ceiling panel 10. Furthermore, in this embodiment, the ribs 20 divide the flow path R in the vehicle width direction, forming a partition flow path R1 extending in the front-rear direction, making it easier for air to flow from the front to the rear.

[0028] In this way, air flows easily through the flow path R and is less likely to stagnate, so that the air in the flow path R is smoothly replaced with new air from the air conditioner 36, and the insulation between the roof panel 91 and the vehicle interior can be improved. For example, in summer, it is possible to reduce the rise in temperature of the vehicle interior due to the heat of the roof panel 91 that has become hot under the blazing sun. Also, for example, in winter, it is possible to reduce the drop in temperature of the vehicle interior due to the outside air. This makes it possible to reduce the overall power consumption of the air conditioner of the vehicle 90, and improve the fuel efficiency and electricity consumption of the vehicle 90. Note that, for example, when the vehicle 90 is an electric vehicle, air may be allowed to flow from the air conditioner 36 through the flow path R during charging. In this way, it is possible to suppress the rise in temperature of the vehicle interior during charging in summer, and it is possible to reduce the power consumption by the air conditioner and the like during driving. Also, in winter, it is possible to melt snow that has fallen on the roof panel 91, and it is possible to save the trouble of removing snow. Furthermore, by flowing air from the air conditioner 36 through the flow path R, it is possible to prevent snow from accumulating on the roof panel 91 while driving, thereby making it possible to extend the driving distance by suppressing the deterioration of air resistance.

[0029] In the ceiling panel 10 of this embodiment, at least the upper part of the protrusion 20 is elastically deformable. Therefore, if the height of the protrusion 20 is made larger than the gap between the roof panel 91 and the panel body 11, the upper part of the protrusion 20 can be compressed and deformed, and the upper end of the protrusion 20 can be brought into close contact with the roof panel by elastic force. This makes it possible to maintain the state in which the air flow path R is partitioned in the vehicle width direction. It is also possible to suppress the generation of noise caused by repeated collisions between the roof panel 91 and the ceiling panel 10. In this way, according to the ceiling panel 10 of this embodiment, even if the height of the protrusion 20 is not exactly the same as the gap between the roof panel 91 and the panel body 11, the upper part of the protrusion 20 can be made to follow the shape of the roof panel 91, and the protrusion 20 can be brought into close contact with the roof panel 91.

[0030] In this embodiment, the protrusion 20 is provided with a compressed portion 26 that is compressed and deformed by being pressed by the cross beam 81, so that it is possible to prevent the protrusion 20 and the cross beam 81 from interfering with each other, making it difficult to attach the ceiling panel 10. In addition, since the protrusion 20 is elastically deformable, it is possible to make the protrusion 20 follow the unevenness of the roof panel 91 side caused by the reinforcement 80 and the like. Moreover, since the upper part of the protrusion 20 is formed of a foamed resin, particularly a soft foamed resin, it is possible to make the protrusion 20 more easily follow the unevenness of the roof panel 91 side. In this way, since the protrusion 20 easily follows the unevenness of the roof panel 91 side, it is possible to make the protrusion 20 adhere to the roof panel 91 and to easily divide the flow path R with the protrusion 20. In addition, since the protrusion 20 adheres to the roof panel 91 and the reinforcement 80 overall in the front-rear direction, it is possible to reduce noise caused by vibration of the roof panel 91 during travel and noise generated by raindrops colliding with the roof panel 91. In addition, since both side portions 21S of the first foamed resin layer 21 of the protrusion 20 have an open cell structure, it becomes possible to absorb sound within the flow path R.

[0031] In this embodiment, the notches 27 that cross the ridge 20 are formed in front and behind the compressed portion 26, making it easier to compress the ridge 20. In addition, by narrowing the distance between the pair of notches 27 that sandwich the compressed portion 26 from the front and rear to approach the width of the cross beam 81 in the front-rear direction, it becomes easier to compress the ridge 20 locally. This makes it possible to prevent the portion of the ridge 20 compressed by the cross beam 81 from expanding in the front-rear direction. As a result, it is possible to prevent the gap between the ridge 20 and the roof panel 91 from becoming larger, making it possible to prevent air from flowing between the partitioned flow paths R1 and causing turbulence or stagnation.

[0032] In this embodiment, the second foamed resin layer 22 made of a second foamed resin harder than the first foamed resin is provided below the first foamed resin layer 21 of the protrusion 20, which increases the strength of the ceiling panel 10. This makes it possible to make the ceiling panel 10 less susceptible to damage when the ceiling panel 10 is assembled to the vehicle 90.

[0033] [Other embodiments] (1) In the above embodiment, the protrusions 20 have a protruding height that makes them contact the roof panel 91, but they may also have a protruding height that does not make them contact the roof panel 91. Also, the protrusions 20 may have a protruding height that does not make them contact the reinforcement 80. Even in these cases, the protrusions 20 can rectify the forward / rearward air flow in the flow path R. Note that when multiple protrusions 20 are provided, only some of the multiple protrusions 20 may have a protruding height that does not make them contact the roof panel 91 or the reinforcement 80.

[0034] (2) In the above embodiment, the ribs 20 have a two-layer structure, but may have a single-layer structure or a three-layer or more structure. When the ribs 20 have a single-layer structure, they may be made of, for example, a foamed resin having an open cell structure or a foamed resin having a closed cell structure. For example, the ribs 20 having a single-layer structure may be made of a soft foamed resin. When the ribs 20 have a laminated structure, it is sufficient that at least the layer constituting the upper part of the ribs 20 is elastically deformable. When the ribs 20 have a three-layer or more structure, for example, the second foamed resin layer 22 may be included in any layer below the first foamed resin layer 21, which is the uppermost layer.

[0035] (3) In the above embodiment, the hardness of the upper layer of the two-layer structure of the ribs 20 can be made greater than or equal to the hardness of the lower layer.

[0036] (4) In the above embodiment, at least the upper portion of the protrusion 20 is an elastically deformable portion, but this elastically deformable portion may be formed of an elastomer such as rubber. Also, the middle portion or lower portion of the protrusion 20 in the vertical direction may be formed of an elastic body such as foam.

[0037] (5) Instead of the notches 27, recesses such as slits 27V (see FIG. 6) that cross the ridges 20 may be formed in front of and behind the compressed portions 26 of the ridges 20.

[0038] (6) In the rib 20, the compressed portion 26 and the portion other than the compressed portion 26 may be formed of different materials. For example, the compressed portion 26 of the rib 20 may be configured to include an elastic body (e.g., a foam) having a lower hardness than the portion other than the compressed portion 26.

[0039] (7) Neither the notches 27 nor the slits 27V need to be provided in the front and rear of the compressed portion 26 of the protrusion 20.

[0040] (8) The protrusions 20 may be integrally formed with the panel body 11.

[0041] (9) In the above embodiment, the ridges 20 have a rectangular cross section, but this is not limited thereto, and the upper surface of the ridges 20 may be a generally arcuate bulging surface, or at least the upper portion of the ridges 20 may have a triangular cross section. In addition, when a plurality of ridges 20 are provided, the ridges 20 do not all need to have the same cross-sectional shape.

[0042] <Additional Notes> The following describes the features extracted from the above embodiment, indicating their effects as necessary.

[0043] For example, the following features 1 to 6 relate to a ceiling panel that is overlaid on a roof panel of a vehicle from below, and can be considered to have been made with the problem that "there is a need for the development of a ceiling panel that is suitable for allowing air to flow between the roof panel and the ceiling panel," in relation to the background technology that "technologies for allowing air to flow between the roof panel and the ceiling panel are known (see, for example, JP 2000-142089 (Figure 1, etc.))."

[0044] [Feature 1] A ceiling panel that is overlapped with a roof panel of a vehicle from below and forms an air flow path between the roof panel and the ceiling panel, A ceiling panel extending in the front-rear direction of a vehicle and having a protrusion on its upper surface, at least an upper portion of which is made of an elastically deformable first foam resin.

[0045] In feature 1, the protrusions extending in the front-rear direction can straighten the air that has flowed between the roof panel and the ceiling panel. By straightening the air in the flow path, it is possible to make it easier for the air in the flow path to flow in the front-rear direction.

[0046] [Feature 2] The ceiling panel according to feature 1, wherein the protrusion has a compressed portion that is compressed and deformed when pressed by a cross beam on the underside of the roof panel.

[0047] In feature 2, the protrusion is provided with a compressed portion that is compressed and deformed when pressed by the cross beam, making it possible to prevent interference between the protrusion and the cross beam that would make it difficult to install the ceiling panel.

[0048] [Feature 3] The ceiling panel according to feature 2, wherein a slit or cut across the protrusion is formed before and after the compressed portion of the protrusion.

[0049] In feature 3, since the slits or cuts crossing the protrusions are formed on the front and rear of the compressed portion, it becomes possible to make the protrusions easier to compress.

[0050] [Feature 4] The ceiling panel according to any one of Features 1 to 3, wherein the protrusions form a laminated structure having a first foamed resin layer formed of the first foamed resin and a second foamed resin layer formed of a second foamed resin having a harderness than the first foamed resin below the first foamed resin layer.

[0051] In feature 4, the second foamed resin layer made of a second foamed resin harder than the first foamed resin is provided below the first foamed resin layer of the protrusion, which increases the strength of the ceiling panel. This makes it possible to make the ceiling panel less susceptible to damage when the ceiling panel is assembled to the vehicle.

[0052] [Feature 5] A ceiling panel according to any one of Features 1 to 4, wherein both side portions of the portion of the protrusion formed by the first foamed resin have an open cell structure.

[0053] According to feature 5, it is possible to absorb sound within the flow path.

[0054] [Feature 6] A ceiling panel according to any one of features 1 to 5, wherein the hardness of the first foamed resin in accordance with JIS K6400-2 D method is 250N or less.

[0055] The hardness of the first foamed resin in accordance with JIS K6400-2 Method D is preferably not more than 250 N. If the first foamed resin has such hardness, it becomes possible to make the protrusions easily conform to the unevenness of the roof panel side.

[0056] In addition, although this specification and drawings disclose specific examples of the technology included in the scope of the claims, the technology described in the claims is not limited to these specific examples, but includes various modifications and variations of the specific examples, as well as parts of the specific examples taken alone. [Explanation of symbols]

[0057] 10 Ceiling Panel 20 protrusions 21 First foamed resin layer 22 Second foamed resin layer 26 Compressed part 27 Cut 27V Slit 81 Crossbeam 90 vehicles 91 Roof Panel R flow path

Claims

1. A ceiling panel that is overlapped with a roof panel of a vehicle from below and forms a flow path between the roof panel and the roof panel, allowing air to pass through in a front-rear direction of the vehicle, a protrusion extending in the front-rear direction and having at least an upper portion formed of an elastically deformable first foamed resin on an upper surface; the protrusion has a laminated structure including a first foamed resin layer formed of the first foamed resin and a second foamed resin layer formed of a second foamed resin having a harderness than the first foamed resin, the second foamed resin layer being disposed below the first foamed resin layer, The ceiling panel has a compressed portion on the protrusion that is compressed and deformed when pressed by a cross beam on the underside of the roof panel.

2. A ceiling panel as described in claim 1, wherein slits or notches crossing the protrusion are formed in front of and behind the compressed portion of the protrusion.

3. A ceiling panel that is overlapped with a roof panel of a vehicle from below and forms a flow path between the roof panel and the roof panel, allowing air to pass through in a front-rear direction of the vehicle, a protrusion extending in the front-rear direction and having at least an upper portion formed of an elastically deformable first foamed resin on an upper surface; the protrusion has a laminated structure including a first foamed resin layer formed of the first foamed resin and a second foamed resin layer formed of a second foamed resin having a harderness than the first foamed resin, the second foamed resin layer being disposed below the first foamed resin layer, The flow path is defined by the protrusion, the ceiling panel, and the roof panel.

4. A ceiling panel described in any one of claims 1 to 3, wherein the hardness of the first foamed resin in accordance with JIS K6400-2 D method is 250 N or less.

5. A ceiling panel that is overlapped from below on a roof panel of a vehicle; a supply duct arranged on a front side of the vehicle relative to the ceiling panel, for supplying air taken in from outside the vehicle; an exhaust duct disposed rearward of the vehicle from the ceiling panel for exhausting air to the outside of the vehicle; A flow path provided between the roof panel and the ceiling panel, for passing air from the supply duct to the exhaust duct in a front-rear direction of the vehicle, The upper surface of the ceiling panel is provided with a plurality of protrusions extending in the front-rear direction and having at least an upper portion formed of an elastically deformable first foamed resin, A flow path for the air is formed between the plurality of protrusions, A vehicle roof structure in which no air conditioning device is provided between the roof panel and the ceiling panel.

Images