Sunroof apparatus

A sunroof apparatus includes: a movable panel adapted to open and close an opening formed in a roof; a guide rail provided in each edge portion of the opening in a width direction, extending in a forward and rearward direction, and including a front end portion in which an attachment hole is formed to open in a vertical direction; a guide block capable of limiting the movement of the movable panel in the forward and rearward direction, and including a body portion mounted in a circumferential edge portion of the attachment hole, a rear limited portion protruding downward from a rear end portion of the body portion, and a front limited portion protruding downward from a front end portion of the body portion; and a holding member tightened to the guide rail, and including a front limiting portion.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 USC. §119 to Japanese Patent Application 2015-150907, filed on Jul. 30, 2015, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to a sunroof apparatus.

BACKGROUND DISCUSSION

In the related art, various types of sunroof apparatuses are proposed (for example, refer to JP 2002-154329A (Reference 1), Japanese Patent No. 4244472 (Reference 2), and Japanese Patent No. 4432211 (Reference 3)). Each of the sunroof apparatuses includes a guide block that limits the movement of a movable panel in a forward and rearward direction of a vehicle during a tilt operation of the movable panel.

In each of the sunroof apparatuses, the fixing of the guide block to a guide rail is described, but a specific fixing structure is not described at all: In contrast, since a substantial load is applied to the guide block from a movable panel side when the movement of the movable panel is limited, desirably, the guide block is rigidly fixed to the guide rail or the like.

SUMMARY

Thus, a need exists for a sunroof apparatus which is not suspectable to the drawback mentioned above.

A sunroof apparatus according to an aspect of this disclosure includes: a movable panel adapted to open and close an opening formed in a roof of a vehicle; a guide rail that is provided in each edge portion of the opening in a width direction of the vehicle, extends in a forward and rearward direction, and includes a front end portion in which an attachment hole is formed in such a way as to open in a vertical direction of the vehicle; a guide block that is capable of limiting the movement of the movable panel in the forward and rearward direction of the vehicle, and includes a body portion mounted in a circumferential edge portion of the attachment hole, a rear limited portion which protrudes downward from a rear end portion of the body portion in the vertical direction of the vehicle, and interposes a rear edge portion of the attachment hole between the body portion and the rear limited portion in the vertical direction of the vehicle, and a front limited portion which protrudes downward from a front end portion of the body portion in the vertical direction of the vehicle, and is inserted into the attachment hole; and a holding member that is tightened to the guide rail, and includes a front limiting portion which is in contact with or is proximate to a vehicle front side of the front limited portion.

DETAILED DESCRIPTION

Hereinafter, an embodiment of a sunroof apparatus will be described. Hereinafter, a “forward and rearward direction” refers to a forward and rearward direction of a vehicle. An “upper side” and a “lower side” respectively refer to an upper side and a lower side of the vehicle in a vertical direction of the vehicle. In addition, a “vehicle interior side” refers to the inside of the vehicle in a width direction of the vehicle, which indicates a passenger compartment side. A “vehicle exterior side” refers to the outside of the vehicle in the width direction, which is closer to the outside of the passenger compartment.

As illustrated inFIG. 1, a substantially rectangular opening10ais formed in a roof10of a vehicle such as an automobile, and a sunroof apparatus11is mounted on the roof10. The sunroof apparatus11includes a substantially rectangular movable panel12made of a glass plate or the like which opens and closes the opening10aby moving in the forward and rearward direction.

The movable panel12is attached such that the movable panel12can be tilted upward, specifically, a rear portion of the movable panel12moves upward in such a way as to turn around a front portion of the movable panel12in one direction, the movable panel12can be tilted downward, specifically, the rear portion moves downward in such a way as to turn around the front portion in the other direction, or the movable panel12can be slid in the forward and rearward direction. The movable panel12is slid while being kept in a tilt-down state during the opening and closing of the movable panel12, that is, a so-called inner sliding type is adopted.

As illustrated inFIG. 2, a pair of guide rails13are respectively disposed in both side edge portions of the opening10ain the width direction of the vehicle. Each of the guide rails13is made of an extruded aluminum alloy or the like, and extends in the forward and rearward direction while having a uniform cross-section in a longitudinal direction of the guide rail13. Sliding members21are respectively guided and supported by the guide rails13such that the sliding members21are capable of moving in the forward and rearward direction. Both side edge portions of the movable panel12in the width direction of the vehicle are respectively linked to and supported by both the sliding members21in a state where the movable panel12is bridged therebetween.

A front side edge portion of the opening10ais provided with a front housing17through which front end portions of both the guide rails13are connected to each other in the width direction of the vehicle. An electric drive source18such as an electric motor with an output gear is installed in a longitudinal middle portion of the front housing17. The electric drive source18is connected to both the sliding members21via a pair of belt-shaped drive belts19made of resin or the like. The electric drive source18simultaneously drives the movement of the sliding members21in the forward and rearward direction. As the sliding members21move along the guide rails13in the forward and rearward direction, the movable panel12is tilted upward, is tilted downward, or is slid.

As illustrated inFIG. 3, a guide block30made of resin or the like is attached to the front end portion of each of the guide rails13. That is, as illustrated inFIG. 5, the guide rail13includes a substantially long rail portion14that extends in the forward and rearward direction (direction perpendicular to the sheet of the drawing), and a belt guide portion15having a substantially C-shaped cross-section which is formed in a vehicle interior side portion of the guide rail13in conjunction with the rail portion14, while opening toward the vehicle exterior side. The rail portion14supports the sliding member21in an area closer to the rear of the vehicle than the guide block30, such that the sliding member21is capable of moving in the forward and rearward direction. The belt guide portion15guides the movement of a drive belt19in the forward and rearward direction. An attachment hole16is formed in a front end portion of the rail portion14, and opens in the vertical direction of the vehicle. As illustrated inFIG. 3, the attachment hole16extends in the forward and rearward direction while the opening width of the attachment hole16changes in the width direction of the vehicle. An insertion hole16ais formed by relatively enlarging the opening of a front end portion of the attachment hole16in the width direction of the vehicle. A pair of fitted pieces14aprotruding toward each other are formed in the rail portion14such that the pair of fitted pieces14aare positioned closer to the rear of the vehicle than the insertion hole16a, and the opening width of the attachment hole16in the width direction of the vehicle is reduced.

The guide block30includes a body portion31which basically has dimensions greater than the opening widths of the attachment hole16in the width direction and the forward and rearward direction of the vehicle, and which is mounted on a circumferential edge portion of the attachment hole16. As illustrated inFIG. 4, the guide block30includes a rear limited portion32having a substantially L-shaped cross-section which protrudes downward from a rear end portion of the body portion31, and interposes a rear edge portion of the attachment hole16between the rear limited portion32and the body portion31in the vertical direction of the vehicle. The guide block30positions the rear edge portion of the attachment hole16in the vertical direction of the vehicle, and limits the movement of the rear edge portion of the attachment hole16toward the rear of the vehicle by interposing the rear edge portion of the attachment hole16between the body portion31and the rear limited portion32in the vertical direction.

As illustrated inFIGS. 4 to 6, the guide block30includes a substantially frame-shaped protrusion portion33which protrudes downward from a front end portion of the body portion31, and is inserted into the attachment hole16. The dimension of the protrusion portion33in the width direction of the vehicle is basically set to be smaller than the opening width of the insertion hole16ain the width direction, and to be larger than a separation distance (opening width of the attachment hole16in the width direction at the position of the fitted pieces14ain the forward and rearward direction) between both the fitted pieces14ain the width direction.

A pair of fitting grooves34having a substantially U-shaped cross-section and acting as fitting portions are formed in a base end portion of the protrusion portion33connected to the body31, and are recessed toward each other such that the dimension of the base end portion is smaller than the separation distance between both the fitted pieces14ain the width direction of the vehicle. The opening width of each of the fitting grooves34in the vertical direction of the vehicle is set to be slightly larger than the plate thickness of the rail portion14. Since both the fitted pieces14aare respectively fitted into both the fitting grooves34, the guide block30is positioned relative to the rail portion14(guide rail13) in the width direction and the vertical direction of the vehicle (limit directions other than the forward and rearward direction of the vehicle). Particularly, as illustrated inFIG. 8, a rib34aprotrudes upward from a lower inner wall surface of each of the fitting grooves34, and extends in the width direction of the vehicle in the range of the lower inner wall surface in the width direction. In a state where the fitted piece14ais fitted into the fitting groove34, a tip end portion of the rib34ais in contact (press contact) with a lower surface of the fitted piece14awhile being squeezed. As a result, fitting between the fitting groove34and the fitted pieces14ais more stabilized. As illustrated inFIG. 4, a front portion of the protrusion portion33forms a front limited portion35. A front end surface of the front limited portion35forms an inclined surface35athat approaches the rear of the vehicle as extending downward.

As illustrated inFIG. 7A, a gap C is formed between an inner wall surface16bof a front end of the insertion hole16a(attachment hole16) and the inclined surface35a(front end surface of the protrusion portion33) of the front limited portion35in the forward and rearward direction such that the gap C is equivalent to at least the range of a margin of engagement between the rear edge portion of the attachment hole16and the rear limited portion32. As illustrated inFIG. 7B, in a state where the guide block30is positioned close to the front of the vehicle relative to the guide rail13by a distance of the gap C, fitting between both the fitting grooves34and both fitted pieces14ais released. Therefore, when the guide block30is attached to the guide rail13, if the guide block30is positioned close to the front of the vehicle relative to the guide rail13by a distance of the gap C, while interference between the attachment hole16and the rear limited portion32and between the attachment hole16and the protrusion portion33is avoided, the rear limited portion32and the protrusion portion33(front limited portion35) can be inserted into the attachment hole16until the body portion31is mounted on the circumferential edge portion of the attachment hole16. If the guide block30in this state is moved toward the rear of the vehicle, the rear edge portion is interposed between the body portion31and the rear limited portion32in the vertical direction of the vehicle, and both the fitting pieces14aare respectively fitted into both the fitting grooves34.

The guide block30forms a portion of a check mechanism (not illustrated) that limits a front end portion of the movable panel12, which is the center of turning when the movable panel12is tilted, from moving in the forward and rearward direction. The check mechanism is configured to release limitation to the movement of the front end portion toward the rear of the vehicle when the movable panel12is opened while being in a tilt-down state, or to limit the turning of the movable panel12(that is, the tilt operation of the movable panel12) around the front end portion when the movable panel12is closed while being in a tilt-down state.

As illustrated inFIG. 5, the body portion31is in contact with or is approximate to the vehicle exterior side of the belt guide portion15. The reason for this is to receive a load, which is applied from the movable panel12when the movement of the movable panel12is limited, via collaboration between the body portion31and the belt guide portion15.

As illustrated inFIGS. 3 and 4, a holding portion40is integrally formed in a tip end portion of the front housing17, and acts as a holding member that receives the front end portions of the guide rails13from the lower side, The front housing17is tightened to the guide rails13via the holding portions40. That is, a bolt insertion hole14bhaving a substantially circular shape or a substantially oval shape is formed in the rail portion14of the guide rail13such that the bolt insertion hole14bis positioned closer to the front of the vehicle than the attachment hole16, and opens in the vertical direction of the vehicle. A nut portion41protrudes downward from the holding portion40at the position of the bolt insertion hole14b.The holding portion40(front housing17) is tightened to the rail portion14(guide rail13) by fastening a screw portion of a bolt46, which is inserted into the bolt insertion hole14bfrom the upper side, to the nut portion41.

Each of the holding portions40includes an extension portion42that extends along a lower surface of the rail portion14from a rear end of the nut portion41toward the rear of the vehicle, and a front limiting portion43that extends downward along the inclined surface35aof the front limited portion35from a rear end of the extension portion42toward the rear of the vehicle. Since the front limiting portion43is in contact with or is proximate to a vehicle front side of the front limited portion35, the movement of the guide block30toward the front of the vehicle is limited.

As illustrated inFIG. 6, multiple (for example, three) ribs44protrude from a front end surface of the front limiting portion43toward the inclined surface35a,and extend in an inclination direction of the front end surface. The ribs44are disposed in the width direction of the vehicle while being spaced regularly, and are in contact (press contact) with the inclined surface35ain a state where tip end portions of the ribs44are squeezed. Therefore, the front limiting portion43more stably limits the movement of the front limited portion35(guide block30).

As described above in detail, according to the embodiment, it is possible to obtain the following operational effects.

(1) In the embodiment, since the rear edge portion of the attachment hole16is interposed between the body portion31and the rear limited portion32in the vertical direction of the vehicle, the movement of the guide block30toward the rear of the vehicle is limited. Since the front limiting portion43of the holding portion40(front housing17) tightened to the guide rail13is in contact with or is proximate to the front limited portion35, the movement of the guide block30toward the front of the vehicle is limited. As such, it is possible to more rigidly fix the guide block30by limiting the movement of the guide block30relative to the guide rail13in the forward and rearward direction.

(2) In the embodiment, since both the fitted pieces14a(inner wall surface of the attachment hole16) are respectively fitted into both the fitting grooves34, the movement of the guide block30relative to the guide rail13in the width direction and the vertical direction (limit directions) of the vehicle is limited. As a result, it is possible to more rigidly fix the guide block30. In a state where the guide block30is positioned close to the front of the vehicle relative to the guide rail13by a distance of the gap C, based on the assumption that the holding portion40is in an untightened state, fitting between both the fitting grooves34and both the fitted pieces14ais released, and there is no margin of engagement between the rear edge portion of the attachment hole16and the rear limited portion32. As a result, it is possible to attach (or detach from) the guide block30to the attachment hole16while avoiding interference therebetween. That is, when the guide block30is attached to the attachment hole16, the body portion31is mounted on the circumferential edge portion of the attachment hole16while the rear limited portion32and the front limited portion35(protrusion portion33) are inserted into the attachment hole16in a state where the guide block30is positioned close to the front of the vehicle relative to the guide rail13by a distance of the gap C. The guide block30in this state is moved toward the rear of the vehicle, the rear edge portion of the attachment hole16is interposed between the body portion31and the rear limited portion32in the vertical direction of the vehicle, and both the fitting grooves34are respectively fitted into both the fitted pieces14a.Thereafter, if the holding portion40(front housing17) is tightened to the guide rail13, the front limiting portion43is in contact with or is proximate to the front limited portion35. In this manner, it is possible to limit the movement of the guide block30relative to the guide rail13in the forward and rearward direction and the limit directions (the width direction and the vertical direction of the vehicle).

(3) In the embodiment, since the ribs44are in contact with the front limited portion35while being squeezed, the front limiting portion43presses the front limited portion35such that the guide block30moves toward the rear of the vehicle, that is, such that the margin of engagement between the rear edge portion of the attachment hole16and the rear limited portion32is maximized. As a result, it is possible to more rigidly limit the movement (wobbling) of the guide block30relative to the guide rail13in the forward and rearward direction, independent of variations in the dimensions of the guide block30.

(4) In the embodiment, since both the fitting grooves34respectively are in contact with or are proximate to both the fitted pieces14ain the width direction of the vehicle, the movement of the guide block30in the width direction is limited. Since both the fitted pieces14aare respectively interposed in both the fitting grooves34in the vertical direction of the vehicle, the movement of the guide block30in the vertical direction is limited. As such, it is possible to more rigidly fix the guide block30by limiting the movement of the guide block30relative to the guide rail13in the width direction and the vertical direction of the vehicle via fitting between both the fitted pieces14aand both the fitting grooves34.

(5) In the embodiment, since both the holding portions40disposed in both guide rails13are formed integrally with the front housing17, it is possible to prevent an increase in the number of components. In other words, it is possible to fix the guide block30via the existing front housing17tightened to the guide rails13. For this reason, dedicated tightening tools (for example, bolts) for fixing the guide blocks30to the guide rails13are not required, and thus, it is possible to reduce the costs of components such as tightening tools, and an assembly cost.

(6) In the embodiment, since contact portions of the front limited portion35and the front limiting portion43are inclined relative to the vertical direction of the vehicle, it is possible to generate a component force to press the guide block30toward the rear of the vehicle when the guide rail13and the holding portion40(the front housing17) are tightened together in the vertical direction via the bolt46. As a result, it is possible to more rigidly limit the movement of the guide block30relative to the guide rail13in the forward and rearward direction.

(7) In the embodiment, in a state where the fitted piece14ais fitted into the fitting groove34, the tip end portion of the rib34ais in contact (press contact) with the lower surface of the fitted piece14awhile being squeezed. As a result, it is possible to more stabilize fitting between the fitting groove34and the fitted piece14a,and for example, it is possible to prevent the wobbling of the guide block30relative to the guide rail13in the vertical direction of the vehicle,

The following changes may be made to the embodiment.In the embodiment, a rib (34a) may protrude downward from an upper inner wall surface (lower surface of the body portion31) of each of the fitting groove34. The rib34aof the fitting groove34may be omitted.In the embodiment, the front limited portion35and the like may extend in the vertical direction of the vehicle without being inclined.

In the embodiment, the holding portion (holding member)40may be a dedicated component separate from the front housing17.

In the embodiment, the ribs44of the front limiting portion43may be omitted. Ribs equivalent to the ribs44may protrude from the inclined surface35aof the front limited portion35toward a rear end surface of the front limiting portion43.In the embodiment, the movement of the guide block30relative to the guide rail13via fitting between the attachment hole and the fitting portions (both the fitted pieces14aand both the fitting grooves34) may be limited in only one direction (the width direction or the vertical direction of the vehicle) other than the forward and rearward direction.In the embodiment, the sunroof apparatus may be an outer sliding type sunroof apparatus in which the movable panel12is opened while being kept in a tilt-up state. Hereinafter, a technical concept which persons skilled in the art can ascertain from the embodiment and the separate examples will be additionally described.

(A) A sunroof apparatus according to an aspect of this disclosure includes; a movable panel adapted to open and close an opening formed in a roof of a vehicle; a guide rail that is provided in each edge portion of the opening in a width direction of the vehicle, extends in a forward and rearward direction, and includes a front end portion in which an attachment hole is formed in such a way as to open in a vertical direction of the vehicle; a guide block that is capable of limiting the movement of the movable panel in the forward and rearward direction of the vehicle, and includes a body portion mounted in a circumferential edge portion of the attachment hole, a rear limited portion which protrudes downward from a rear end portion of the body portion in the vertical direction of the vehicle, and interposes a rear edge portion of the attachment hole between the body portion and the rear limited portion in the vertical direction of the vehicle, and a front limited portion which protrudes downward from a front end portion of the body portion in the vertical direction of the vehicle, and is inserted into the attachment hole; and a holding member that is tightened to the guide rail, and includes a front limiting portion which is in contact with or is proximate to a vehicle front side of the front limited portion.

With this configuration, since the rear edge portion of the attachment hole is interposed between the body portion and the rear limited portion in the vertical direction of the vehicle, the movement of the guide block toward the rear of the vehicle is limited. Since the front limiting portion of the holding member tightened to the guide rail is in contact with or is proximate to the front limited portion, the movement of the guide block toward the front of the vehicle is limited. As such, it is possible to more rigidly fix the guide block by limiting the movement of the guide block relative to the guide rail in the forward and rearward direction of the vehicle.

(B) In the sunroof apparatus, a gap is formed between the attachment hole and the front limited portion in the forward and rearward direction of the vehicle such that the gap is equivalent to at least the range of a margin of engagement between the rear edge portion of the attachment hole and the rear limited portion, and the guide block includes a fitting portion which limits the movement of the guide block relative to the guide rail in a limit direction other than the forward and rearward direction of the vehicle by being fitted into the attachment hole, and is capable of releasing fitting between the guide block and the attachment hole in a state where the fitting portion is positioned close to the front of the vehicle relative to the guide rail by a distance of the gap.

With this configuration, since the fitting portion is fitted into the attachment hole, the movement of the guide block relative to the guide rail in the limit direction is limited. As a result, it is possible to more rigidly fix the guide block. In a state where the guide block is positioned close to the front of the vehicle relative to the guide rail by a distance of the gap, based on the assumption that the holding member is in an untightened state, fitting between the fitting portion and the attachment hole is released, and there is no margin of engagement between the rear edge portion of the attachment hole and the rear limited portion. As a result, it is possible to attach (or detach from) the guide block to the attachment hole while avoiding interference therebetween,

(C) In the sunroof apparatus, a rib protrudes from the front limiting portion, and is in contact with the front limited portion while being squeezed.

In this configuration, since the rib is in contact with the front limited portion while being squeezed, the front limiting portion presses the front limited portion such that the guide block moves toward the rear of the vehicle, that is, such that a margin of engagement between the rear edge portion of the attachment hole and the rear limited portion is maximized. As a result, it is possible to more rigidly limit the movement of the guide block relative to the guide rail in the forward and rearward direction of the vehicle.

(D) In the sunroof apparatus, a pair of fitted pieces protruding toward each other are formed in the guide rail such that the opening width of the attachment hole in the width direction of the vehicle is reduced. A pair of fitting grooves are formed in the fitting portion such that both the fitting grooves respectively are in contact with or are proximate to both the fitted pieces in the width direction of the vehicle, and both the fitted pieces are respectively interposed in both the fitting grooves in the vertical direction of the vehicle.

In this configuration, since both the fitting grooves respectively are in contact with or are proximate to both the fitted pieces in the width direction of the vehicle, the movement of the guide block in the width direction is limited. Since both the fitted pieces are respectively interposed in both the fitting grooves in the vertical direction of the vehicle, the movement of the guide block in the vertical direction is limited. As such, it is possible to more rigidly fix the guide block by limiting the movement of the guide block relative to the guide rail in the width direction and the vertical direction of the vehicle via fitting between both the fitted pieces and both the fitting grooves.

(E) In the sunroof apparatus, both the holding members are formed integrally with a front housing through which front end portions of both the guide rails are connected to each other in the width direction of the vehicle.

In this configuration, since both the holding members are formed integrally with the front housing, it is possible to prevent an increase in the number of components.

According to the aspect of this disclosure, it is possible to more rigidly fix a guide block.