Abstract:
A modular roof of an automobile ( 1 ) comprising a bodyshell roof structure ( 2 ) which has a front and rear transverse member ( 3  or  4 ) and a right and left side member ( 5  or  6 ). The modular roof has at least two modular roof elements ( 7, 14, 15 ) which are fixed directly to the roof structure ( 2 ). The modular roof elements ( 7, 14, 15 ), which extend over the entire breadth of the roof structure, are preferably fixed, especially releasably fixed, to the side members ( 5, 6 ) which lie opposite each other.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to a modular roof for a motor vehicle having a roof shell structure with a front and a back cross member and a right and a left side member. 
   2. Description of Related Art 
   Mounting a sliding roof on the top part of the roof of a conventional motor vehicle which has a roof structure especially made of sheet metal is known. Conventionally, an opening is made in the top part of the roof and then the sliding roof unit is installed. However, even if high quality installation is possible in this way, producing an opening represents an additional working process in addition to the conventional processes of shaping the top part of the roof. Likewise, the equipment necessary for producing this opening requires additional investment compared to that which is necessary for a conventional motor vehicle without a sliding roof. 
   Published German Patent Application DE 35 45 871 A1, and counterpart published UK Patent Application 2 184 404 A, disclose a vehicle roof which has an installation unit in the form of a roof cap which can be placed later on at least the side roof members of a roof structure and can be fixed thereto. A ready-mounted ventilation means such as, for example, a sliding roof or a spoiler roof is integrated into the roof cap. However, different roof caps, which as an installation unit, always have the same size which is matched to the location of the roof members so that it can be attached to the roof members. 
   U.S. Pat. No. 5,540,478, discloses a roof structure for a motor vehicle in which the vehicle manufacture provides a roof shell with dimensionally defined master mounting points to which a modular roof insert, which is completely premounted by the supplier with a sunroof, can be mounted. In this way, regardless of the roof superstructure of the different roof parts to be attached thereto, assembly always takes place at the same master mounting points at the vehicle manufacturer. 
   SUMMARY OF THE INVENTION 
   The primary object of this invention is to devise a generic modular roof which enables a more variable configuration of the vehicle roof with simplified production, and a motor vehicle with such a modular roof. 
   This object is achieved in a general modular roof by the modular roof having at least two roof module elements which are attached directly to the roof structure. By selective combination of at least two roof module elements, diversely configured modular or vehicle roofs can be formed, the cost necessary for this purpose being much less than if each desired version had to be warehoused as a complete part. 
   Preferably, the roof module elements which extend over the entire width of the roof structure are mounted on the opposing side members so that intermediate elements or the like are not necessary. If the roof module elements are detachably mounted, a mounted modular roof can be converted by replacement of the roof module elements. 
   Variability of the modular roof is ensured by the cross members and the side members bordering a roof structure opening which can be closed partially or completely by at least two roof module elements. 
   A roof opening which remains between two roof module elements or between one roof module element and one cross member can be closed by a least one other roof module element. In general, the roof module elements can be covers, transparent covers, glass covers or functional roof parts such as openable roof parts and especially sliding roof units. 
   Feasibly, the roof structure is made of sheet metal, but also other materials, such as high-strength plastics can be used. 
   The individual roof module elements can be made frameless or they can have a frame, especially as a sliding roof unit. A roof module element or a sliding roof unit can have a frame with a front and a back cross frame element and a right and a left side frame element and can hold a cover which is movably supported on the frame, each of the side frame elements comprising means for attaching this side frame element to the respective side member and each of the cross frame elements extending over the entire width of the roof structure between the two side members. 
   In one simple configuration, the front cross frame element can be designed for direct attachment to the cross member on the top edge of the windshield and the back cross frame element for direct attachment to the cross member on the top edge of the rear window. 
   Preferably, each frame element which is attached directly to the assigned member of the roof structure has means so that, with the interposition of a seal, it rests on a flange which is provided on the inside of the member. 
   Feasibly, the sliding roof unit can be attached to the roof structure as a partial system which is completely prefabricated with an inner lining. In general, each roof module element which contains additional components can be prefabricated so that final installation on the vehicle roof is simplified. 
   To achieve this object in a motor vehicle with an especially sheet metal roof structure for holding a modular roof which is made according to the aforementioned statements, it is proposed that the motor vehicle, in a respective modular roof, holds alternatively, an openable roof unit which is installed between a front roof module element and a back roof module element, or an openable roof unit which is installed between the front cross member and the back roof module element, or an openable roof unit which is installed between the back cross member and a front roof element or the front cross member and that the openable roof unit is especially a sliding roof unit. 
   Embodiments of the invention are explained in detail below with reference to the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic top view of a roof structure of a modular roof of a motor vehicle; 
       FIG. 2  is a schematic perspective view of the installation of a sliding roof unit and other roof module elements according to one embodiment of this invention; 
       FIG. 3  is a view similar to  FIG. 2  of another embodiment of this invention; 
       FIG. 4  is an enlarged sectional view along section plane IV—IV in  FIG. 1  of the embodiment shown in  FIG. 2 ; 
       FIG. 5  is an enlarged sectional view along section plane V—V in  FIG. 1  of the embodiment shown in  FIG. 2 ; 
       FIG. 6  is an enlarged sectional view along section plane VI—VI in  FIG. 1  of the embodiment shown in  FIG. 2 ; 
       FIG. 7  is a view similar to  FIG. 4  of the embodiment shown in  FIG. 3 ; 
       FIG. 8  shows, in views  8 A,  8 B, and  8 C, three different modular roofs of this invention for the same motor vehicle; 
       FIG. 9  shows, in views  9 A,  9 B, and  9 C, schematic perspectives which correspond, respectively, to the modular roofs of  FIGS. 8A ,  8 B, and  8 C; 
       FIG. 10  is a perspective overhead view of the shell of a motor vehicle with a roof structure for the modular roof; 
       FIG. 11  shows, in views  11   a ,  11   b , and  11   c , a modular roof made of different roof module elements. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The shell of a motor vehicle  1  with a modular roof contains a roof structure  2  (see  FIG. 1  and  FIG. 10 ) with a front cross member  3  on the top edge of the windshield, a back cross member  4  on the top edge of the rear window and a right and a left side member  5  and  6 . The members  3 ,  4 ,  5 , and  6  surround the roof structure opening  35  of the shell. The reference direction which corresponds to the forward direction of motion of the motor vehicle  1  is shown schematically by the arrow  1   a  in  FIG. 1 . 
   Roof module elements such as, for example, the front roof module element  14  (see  FIGS. 2 ,  11   b  and  c ), a back roof module element  15  and a sliding roof unit  7  supplement and complete the modularly built modular roof in a selectively fixable arrangement, especially the front and the back roof module element  14  and  15  being available and installable in different sizes. 
   The sliding roof unit  7  contains a frame  8  (see  FIG. 2 ) which is formed by a front and a back cross frame element  9  and  10  and by a right and a left side frame element  11  and  12 . A sliding roof cover  13  is movably supported on the frame  8 . These sliding roofs are known and therefore are not explained in detail. Each of the side frame elements  11 ,  12  contains means for attaching this frame element  11 ,  12  to the assigned side member  5 ,  6  of the roof structure and each of the cross frame elements  9 ,  10  extends between the two side members  5 ,  6  over the entire width of the roof structure  2 . 
   In the embodiment shown in  FIG. 2 , the sliding roof unit  7  is installed between the front roof module element  14  and the back roof module element  15  which are attached to the front cross member  3  or the back cross member  4 . 
   In the embodiments shown schematically in  FIG. 3 , the roof structure  2  contains a sliding roof unit  16  with a front cross frame element  9  which is directly attached to the front cross member  3 , and with a back cross frame element  10  which is directly attached to the back cross member  4 . In this case, the transition between the sliding roof unit  16  and the rear window can be made in any manner. 
   The roof structure  2  can also comprise several sliding roof units for producing a modular roof; they have different lengths in the lengthwise direction of the vehicle so that they can be connected to front and back roof module elements  14 ,  15  of different dimensions, and in the case of direct attachment of the front or the back cross frame element  9  and  10 , to the front cross member  3  or to the back cross member  4 , these roof module elements  14 ,  15  can be omitted. 
     FIGS. 8A ,  8 B,  8 C and  9 A,  9 B,  9 C 1  and  9 C 2  show three embodiments of modular roofs for the same motor vehicles. 
   The roof module element  7   a  which forms the sliding roof unit and which is shown schematically in  FIGS. 8A and 9A  covers a small portion, for example, roughly one third of the surface of the modular roof or the roof structure opening  35 . It is connected to the front roof module element  14   a  and the back roof module element  15   a  of relatively great length. 
   The roof module element  7   b  (see  FIGS. 8B and 9B ) is connected to a front and a back roof module element  14   b  and  15   b  of smaller lengths which essentially cover the cross members  3  and  4  of the roof structure  2 . 
   The roof module element  7 C 1  (see  FIGS. 8C and 9C   1 ) forms essentially the entire top part of the modular roof. There still remains a back roof module element  15 C 1  which is, for example, necessary to produce the connection to the rear hatch. 
   The roof module element  7 C 2  (see  FIG. 9C   2 ) forms essentially the entire top part of the roof. The connections between the roof module element or the sliding roof unit  7 C 1  or  7 C 2  to the windshield, and optionally to the rear window, can be produced in any known manner. 
     FIGS. 11   a ,  11   b  and  11   c  again show three embodiments of the modular roof. The modular roof can selectively have a cover  36  which closes the entire roof structure opening  35 , for example, a sheet metal or glass cover ( FIG. 11   a ). A second version of the modular roof ( FIG. 11   b ) contains a front and a back fixed roof module element  14  and  15  and a sliding roof unit  7  located in between, the back roof module element  15  being much larger than the front roof module element  14 . A third version of the modular roof ( FIG. 11   c ) contains a front and a back fixed roof module element  14  and  15  which have roughly the same size, a sliding roof unit  7  located in between and another cover  37  which can be a fixed cover or a sliding roof cover. 
   As is shown in  FIGS. 4 to 7 , each frame element  9  to  12  which is attached directly to the corresponding member  3  to  6  of the roof structure  2  comprises means so that, with the interposition of a seal  17 , it can rest on a flange  18  which is provided on the inside of the members  3 ,  4 ,  5 ,  6 . 
   In the embodiment shown in  FIG. 4 , the front roof module element  14  covers the front cross member  3  and a reinforcing sheet  19  which is attached to the back end of the front roof module element  14  and forms the flange  18 . The front end of the front cross frame element  9  ends with a covering  20  which is essentially parallel to the flange  18  and which has a folded-down front edge  21  which rests on the flange  18 , its pressing on a cement strip  17  which forms a seal. The cement strip  17  contains, for example, a polyurethane cement. A visible, prefabricated headliner lining  22  on the front cross frame element covers a drive motor  23  and cables  24 ,  25  for driving the movable cover  13  of the sliding roof unit. 
   In the embodiment shown in  FIG. 5 , the side frame element  12  of the frame  8 , which is located exactly over the flange  18  of the front left side member  6 , on the bottom of the covering  20  bears a cement strip  17  which is not yet pressed together. A unit  26  which forms the side guide rail of the sliding roof cover  13  is covered laterally towards the vehicle interior by a wall  27  with a visible surface which is covered, in the conventional manner, with a fabric  28 . The headlining  29  which comprises, for example, one or more handles and one or more airbags (not shown) is mounted in the conventional manner on the side member  6 . 
   In the embodiment shown in  FIG. 6 , the back roof module element  15 , on its bottom, comprises a ribbed reinforcement  30  which, together with the roof module element  15 , forms the flange  18 . The visible, prefabricated headlining  31  is attached to the back cross frame element  10 . 
   In the embodiment shown in  FIG. 7 , the front roof module element  14  covers the front cross member  3 , which has a rear U-shaped profile section with an end section  32 , with an outer leg which runs downward and a flange  18  which is then bent to the back. 
   The sliding roof unit  7 ,  16  is prefabricated such that it can be mounted on the roof structure opening  35  of a vehicle  1  as a complete modular parts system which is provided with an inner headlining. 
   As is shown schematically in  FIGS. 2 and 3 , first the front roof module element  14  and the back roof module element  15  (if this is present) are mounted. Thereupon, the sliding roof unit  7 ,  16  is placed on the roof structure  2  (arrow  33  in  FIG. 3 ). Then, the front headlining  22 , the side headlining  29  and the back headlining  31  (arrows  34 ) can be mounted. 
   Thus, the described modular roof of simple structure has roof module elements which can be located and can be attached directly to the side roof members  5 ,  6  of the, for example, sheet metal roof structure  2  of a vehicle, and other elements, for example, a front and/or a back roof module element  14  and  15  can be added to the modular roof easily and economically. 
   The linings, optionally with additional components such as a sunshade, handles, etc., can then be mounted in the conventional manner. 
   Such a modular roof enables a reduction of installation and investment costs, offers the advantages of modularity with the same vehicle type, and larger and thus more efficient opening of the sliding roof by there being complete structural freedom with respect to the execution of the inner and outer shapes. 
   The conventional interfaces with respect to seals, water drain tubes and means for adjusting the movable cover can also be reduced by such a modular roof. 
   Such a modular roof enables simple installation of accessories, such as, for example, an antenna, an operating console or a cable harness, etc. 
   This invention is not limited to the described embodiments, but rather numerous modifications and changes can be undertaken without going beyond the framework of the invention.