Vehicle roof structure

Abstract

To provide a roof for a vehicle which prevents a roof panel from interfering with a roof member, and which prevents abnormal noises from being generated due to a contact between the roof panel and the roof member.SOLUTION: A roof 10 for a vehicle includes: a roof panel 12 of a vehicle body; a roof member 11 which extends in the vehicle widthwise direction relative to the roof panel 12, and which reinforces the roof panel 12 from the interior side of the vehicle body; a mastic sealer 15 which is placed on the roof member 11, and which joins the roof member 11 with the roof panel 12; a bracket 17 which includes a base portion 17b1 that protrudes toward the roof panel 12, and an extended plate 17b2 bent from the base portion 17b1 and provided so as to extend along the roof member 11, and which is fastened to the roof member 11; and a solid foam member 18 which covers the base portion 17b1 and the extended plate 17b2, and which is formed so as to have a predetermined clearance from the roof panel 12.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a roof structure for a vehicle such as an automobile. [Background technology]

[0002] Generally, a roof panel of a vehicle is reinforced by being supported from the inside by a long roof member. To maintain the aesthetic appeal of the roof panel, the roof panel and roof member are joined using a thermosetting elastic adhesive called mastic sealer instead of welding. Mastic sealer is a loosely kneaded mixture or gel in its uncured state, and when baked and dried during the painting process, it hardens to provide a rubber-like adhesive strength. Incidentally, roof panels vibrate up and down due to cleaning during the electrodeposition coating process, which is carried out before the mastic sealer has hardened, the flow of electrodeposition liquid in the electrodeposition coating tank, and vibrations during transport to the coating process. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Utility Model Application Publication No. 63-54590 Summary of the Invention [Problem to be solved by the invention]

[0004] However, due to the vertical vibrations that occur during the electrodeposition coating process, etc., the uncured mastic sealer that has been crushed by the roof panel may repeatedly expand and contract up and down, causing it to peel off from the roof panel or roof member. If the mastic sealer peels off, it may cause damage to the roof panel or roof member when the roof panel vibrates during driving or when the door is opened and closed. ,gold The contact between the parts causes unpleasant noises.

[0005] The present invention has been made in consideration of the above circumstances, and aims to provide a vehicle roof that prevents interference between the roof panel and the roof member and prevents the generation of abnormal noise due to contact between the roof panel and the roof member. [Means for solving the problem]

[0006] The roof of the vehicle according to this embodiment includes a roof panel of a vehicle body, a roof member extending in the vehicle width direction relative to the roof panel and reinforcing the roof panel from the inside of the vehicle body, and a mastic sealer disposed on the roof member and joining the roof member and the roof panel together. Attached to the roof member A bracket and The foamed member is held by the bracket between the roof member and the roof panel. A solid foam material; A foam cushioning material having Preparation The bracket includes a base plate that is fixed to the roof member and extends along the surface of the roof member, a base that protrudes from the base plate toward the roof panel, and an extension plate that bends from the base and extends between the roof member and the roof panel, sandwiching the base plate between the bracket and the roof member and having a gap between the bracket and the base plate, and the solid foam material fills a semi-closed space surrounded by the base plate, the base, and the extension plate, covers the base and the extension plate, and is formed to have a predetermined gap from the roof panel. This is what is done. [Effects of the Invention]

[0007] The present invention provides a vehicle roof that prevents interference between the roof panel and the roof member, and prevents the generation of abnormal noise due to contact between the roof panel and the roof member. [Brief explanation of the drawings]

[0008] [Figure 1] 1A is a schematic diagram of the roof of a vehicle according to an embodiment, viewed from the inside of the vehicle, excluding the interior, and FIG. 1B is an enlarged perspective view of the roof member in the Ω range of FIG. 1A. [Figure 2] 1(A) and 1(B) are diagrams showing the foam cushioning material before foaming, where (A) is a perspective view, (B) is a top view, and (C) is a cross-sectional view of the Ω range in FIG. 1(A) cut along line II. [Figure 3] 1(A) and 1(B) are diagrams showing the foam cushioning material after foaming, where (A) is a perspective view, (B) is a top view, and (C) is a cross-sectional view of the Ω range of FIG. 1(A) cut along line II. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. In the embodiment, the reference for the "up-down" direction and the "vehicle width" direction of each member is the up-down direction and the vehicle width direction of the vehicle when the member is installed on the vehicle.

[0010] FIG. 1(A) is a schematic diagram of a roof 10 of a vehicle according to an embodiment, viewed from the inside of the vehicle, excluding the interior, and FIG. 1(B) is an enlarged perspective view of a roof member 11 in the Ω range of FIG. 1(A). As shown in FIG. 1(A), a roof 10 of a vehicle is configured by reinforcing a roof panel 12 fixed to a body frame with roof members 11 by welding from the inside of the vehicle. The roof member 11 is fixed along the vehicle width direction at a position where the vertical vibration of the roof panel 12 becomes large. In most cases, the roof member 11 supports the roof panel 12 with a plurality of members. In order to increase the strength of the roof member 11, as shown in Fig. 1(B), a plurality of ridges 14 are provided on the surface of the roof member 11, generally along the longitudinal direction of the roof member 11. The ridges 14 are formed with a top surface 14a having a predetermined width.

[0011] For example, cylindrical or rectangular parallelepiped mastic sealer 15 is applied to multiple locations on top surface 14a. Mastic sealer 15 dries and hardens when baked in a heating furnace after the vehicle body is electrocoated. After hardening, mastic sealer 15 bonds roof panel 12 and roof member 11 together with its own adhesive strength.

[0012] However, as mentioned above, some of the mastic sealer 15 may peel off from the roof member 11 during the manufacturing process. Therefore, foam cushioning material 16 is placed near the mastic sealer 15 to prevent collision between the roof member 11 and the roof panel 12. The mastic sealer 15 is placed in a location where vibration of the roof panel 12 is greatest. Accordingly, the foam cushioning material 16 is also placed in a location where vibration of the roof panel 12 is greatest. The specific installation location of the foam cushioning material 16 is identified, for example, using the finite element method, as the location where the amount of deformation is greatest when the flange on the outer periphery of the roof panel 12 is restrained and uniform water pressure is applied to the entire design surface of the roof panel 12. The installation location of the foam cushioning material 16 is determined, for example, within a range of 30 cm from the location where the amount of deformation is greatest. In terms of its position relative to the mastic sealer 15, it is placed within a range of, for example, 50 cm from the mastic sealer 15. The distance from the mastic sealer 15 is more preferably within 30 cm.

[0013] Next, Figures 2(A) to 2(C) are diagrams showing the foam cushioning material 16 before foaming, and Figures 3(A) to 3(C) are diagrams showing the foam cushioning material 16 after foaming. Figures 2(A) and 3(A) are perspective views of the foam cushioning material 16 and its surroundings. Figures 2(B) and 3(B) are top views of the foam cushioning material 16 and the roof member 11. Figures 2(C) and 3(C) are cross-sectional views of the roof member 11 taken along line II in the Ω range of Figure 1(A).

[0014] As shown in Figures 2(A) to 2(■) and Figures 3(A) to 3(C), the foam cushioning material 16 is composed of a bracket 17 fixed to the roof member 11 and a solid foam material 18 placed on the bracket 17. The bracket 17 is formed such that, for example, the mounting legs 17a (17) and the holding mechanism 17b (17) are integrally formed on one base plate 17c in a front-back relationship.

[0015] The mounting foot 17a is inserted into a mounting hole 19 formed in the roof member 11. The mounting foot 17a is formed with a skirt-shaped locking claw 17a1 that widens from the top of the mounting foot 17a toward the base plate 17c (17). When the mounting foot 17a is fully inserted into the mounting hole 19, the skirt shape of the locking claw 17a1, which was once squeezed by the mounting hole 19, returns to its natural shape and widens beyond the mounting hole 19, and the locking claw 17a1 locks onto the edge of the mounting hole 19. The locking claw 17a1 locks onto the edge of the mounting hole 19, fixing the mounting foot 17a to the mounting hole 19, and thus fixing the bracket 17 to the roof member 11. The shape of the mounting foot 17a is not limited to the above-described configuration, as long as the mounting foot 17a can be fixedly locked into the mounting hole 19.

[0016] The holding mechanism 17b is configured by integrally forming a base portion 17b1 that protrudes toward the roof panel 12 and an extension plate 17b2. 2(B) and 3(B), the base 17b1 has a shape in which two arc-shaped portions face each other with a predetermined gap 21 between them when viewed from above the bracket 17. The extension plate 17b2 is bent from the base 17b1 and extends along the roof member 11.

[0017] Unfoamed solid foam material 18 is applied to the surface of this extension plate 17b2 facing the roof panel 12 and to the semi-closed space 22 sandwiched between the holding mechanism 17b and the base plate 17c. The solid foam material 18 is made of a foamable material such as urethane, polyethylene, or rubber. The solid foam material 18 applied to the retention mechanism 17b foams and expands due to heating and drying after the electrodeposition coating process, covering the base 17b1 and the extension plate 17b2 and filling the space between the roof panel 12 and the roof member 11. After expansion is complete, the solid foam material 18 becomes a baffle material formed so as to be spaced a predetermined distance from the roof panel 12.

[0018] In its uncured state, the solid foam material 18 is hard enough to withstand being crushed by deformation of the roof panel 12 during the painting process, and when heated, it foams and turns into a soft sponge-like material. Therefore, the foam cushioning material 16 functions as a solid spacer during pre-painting and electrodeposition painting processes. To function as a spacer to prevent deformation of the roof panel 12 during the painting process, the uncured solid foam material 18 is applied so as to maintain a gap of approximately 1 mm between the roof panel 12 and the foam material 18.

[0019] However, in the initial stage of foaming of the solid foam material 18, the solid foam material 18 still has a certain degree of hardness, and its expansion force pushes up the roof panel 12, which may cause the adjacent mastic sealer 15 to peel off.

[0020] Therefore, by extending the extension plate 17b2 along the upper surface of the roof member 11, the expansion direction is guided along the roof member 11 in the early stage of foaming. The guidance by the extension plate 17b2 makes it possible to suppress the expansion of the solid foam material 18 toward the roof panel 12.

[0021] Furthermore, in order to further suppress the expansion of the solid foam material 18 toward the roof panel 12, it is desirable that the tip of the extension plate 17b2 be inclined toward the roof member 11. In other words, in the early stages of foaming, it is desirable that the outer peripheral surface contour of the solid foam material 18 curves and expands so as to bulge toward the roof member 11. It is also desirable that the length of the extension plate 17b2 along the roof member 11 be designed to be longer than the height of the base 17b1 so that the solid foam material 18 is reliably aligned along the roof member 11. Furthermore, it is desirable to apply the solid foam material 18 arranged on the upper surface side of the extension plate 17b2 so that the volume of the solid foam material 18 in the semi-closed space 22 formed by the retaining mechanism 17b and the roof member 11 is smaller.

[0022] In order to expand the solid foam material 18 uniformly, the base 17b1 is preferably ring-shaped, as exemplified by the two arc-shaped bases 17b1 facing each other with a predetermined gap 21 between them. That is, as shown in FIGS. 2(B) and 3(B), by providing a through-hole 23 in the base 17b1 in a top view, a space for the solid foam material 18 to expand can be secured in the center of the bracket 17 during the initial stage of expansion. The ring-shaped base 17b1 is also preferably provided with a slit (gap) 21 that cuts the ring. Providing the slit 21 can prevent the electrodeposition solution from stagnating during the electrodeposition coating process, improving electrodeposition adhesion. .

[0023] As described above, according to the embodiment, the unfoamed foam cushioning material 16 suppresses vibration of the roof panel 12 during the electrodeposition coating process, etc., thereby reducing the amount of deformation of the mastic sealer 15. This prevents the mastic sealer 15 from peeling off the roof member 11 and the roof panel 12. Furthermore, after the solid foam material 18 has foamed, the area where the foam cushioning material 16 is placed is filled with a sponge-like elastic body, preventing interference between the roof panel 12 and the roof member 11. This prevents the generation of abnormal noise due to contact between the roof panel 12 and the roof member 11.

[0024] Furthermore, in the areas where the foam cushioning material 16 is placed, deformation of the roof panel 12 is reduced when a user applies weight to the roof panel 12, for example, when washing the car. Therefore, the roof panel 12 can be kept thin while giving the user the impression of a more solid vehicle body. Furthermore, by reducing the deformation of the roof panel 12, the amount of mastic sealer 15 to be applied can be reduced accordingly, thereby shortening the takt time for manufacturing the vehicle body. Furthermore, unlike ordinary metal spacers, the foam cushioning material 16 is not in contact with the roof panel 12 in the initial state, so no unpainted surface is left on the roof panel 12. Therefore, there is no risk of rust developing on the unpainted surface of the roof panel 12.

[0025] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, substitutions, modifications, and combinations can be made without departing from the spirit of the invention. These embodiments and their variations are intended to be included in the scope of the invention and its equivalents as described in the claims, as well as in the scope and spirit of the invention.

[0026] For example, the foam cushioning material of the present invention can be applied to the hood and doors, which also vibrate. Also, by giving the foam cushioning material sound-absorbing properties, the sound of rain falling on the roof panel can be reduced. [Explanation of symbols]

[0027] 10...roof, 11...roof member, 12...roof panel, 14...ridge portion, 14a...top surface, 15...mastic sealer, 16...foam cushioning material, 17 (17a to 17c)...bracket, 17a...mounting foot, 17a1 (17a)...locking claw, 17b (17b1, 17b2)...retaining mechanism (base, extension plate), 17c...foundation plate, 18...solid foam material, 19...mounting hole, 21...gap (slit groove), 22...semi-enclosed space, 23...through hole

Claims

1. The roof panel of the vehicle body, a roof member extending in a vehicle width direction relative to the roof panel and reinforcing the roof panel from the inside of the vehicle body; a mastic sealer disposed on the roof member to bond the roof member to the roof panel; a foam cushioning material including a bracket attached to the roof member and a foamed solid foam material held by the bracket between the roof member and the roof panel, The bracket is a base plate that is fixed to the roof member and extends along the surface of the roof member; a base portion protruding from the base plate toward the roof panel; an extension plate that is bent from the base and extends between the roof member and the roof panel, sandwiching the base plate between the extension plate and the roof member and having a gap between the extension plate and the base plate, A vehicle roof structure characterized in that the solid foam material fills the semi-closed space surrounded by the base plate, the base, and the extension plate, covers the base and the extension plate, and is formed so as to be spaced a predetermined distance from the roof panel.

2. 2. The vehicle roof structure according to claim 1, wherein a tip of the extension plate is inclined toward the roof member.

3. A vehicle roof structure as described in claim 1 or claim 2, wherein the volume of the solid foam material arranged on the surface of the extension plate facing the roof panel before foaming is smaller than the volume of the solid foam material arranged in the semi-closed space before foaming.

4. 4. The vehicle roof structure according to claim 1, wherein the base portion has an arc shape or an annular shape when viewed perpendicularly to the roof member from the outside of the vehicle body.

5. The vehicle roof structure according to claim 4 , wherein the base portion of the ring shape is provided with a notch for cutting the ring.

6. 6. The vehicle roof structure according to claim 1, wherein a height of the base portion is shorter than a length of the extension plate along the roof member.

7. 7. The vehicle roof structure according to claim 1, wherein the solid foam material is disposed within 50 cm of the mastic sealer.

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