Roof apparatus for vehicle

A roof apparatus for a vehicle, includes a pair of guide rails, a movable panel, a housing, a casing, and a first spur tooth rack belt and a second spur tooth rack belt for transmitting a drive force of a drive mechanism to the movable panel. The first spur tooth rack belt includes plural first spur teeth and the second spur tooth rack belt includes plural second spur teeth, and a slope portion inclined upward toward a rear side of the vehicle is provided forward of each of the pair of guide rails. A pair of guide portions is provided at each of the guide rails for guiding the first spur tooth rack belt and the second spur tooth rack belt. A cutout portion is formed at a front end portion of each of the guide rails.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 U.S.C. §119 to Japanese Patent Application 2010-248133, filed on Nov. 5, 2010, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

This disclosure generally relates to a roof apparatus for a vehicle.

BACKGROUND DISCUSSION

A known roof apparatus for a vehicle includes a pair of left side and right side guide rails, a movable panel, a housing and a pair of drive force transmitting members. The pair of guide rails extends along a front/rear direction of a vehicle along both side portions of an opening portion formed on a roof of the vehicle. The movable panel for opening and closing the opening portion is supported by the pair of guide rails so as to be slidable in the front/rear direction of the vehicle. The housing extends in the width direction of the vehicle along a front portion of the opening portion and is connected to a front end surface of each of the pair of guide rails. A drive mechanism and a casing are provided at the housing. The drive force transmitting member is inserted into the casing. The drive force transmitting member is guided by and slides along the casing and the pair of guide rails, and thus moves the sliding panel in the front/rear direction of the vehicle for opening and closing the opening.

For example, a sunroof device for use in a vehicle in which drive cables are used as the drive force transmitting member is disclosed in JPH7-149153A (hereinafter referred to as Patent reference 1). The sunroof device for use of the vehicle according to the Patent reference 1 is constituted by the housing, and a guide plate which is fixedly attached to a lower face of the housing and into which the drive cables are inserted.

In a sliding roof device disclosed in JP3659632B (hereinafter referred to as Patent reference 2), spur tooth rack belts are used instead of the above-stated drive cables as the drive force transmitting member. Each of the spur tooth rack belts includes spur teeth protruding in a direction perpendicular to a longitudinal direction of the spur tooth rack belt in a manner that the surfaces, on which the spur teeth are formed, of the spur tooth rack belts face each other.

However, in case that the spur tooth rack belts disclosed in the Patent reference 2 are used as the drive force transmitting member of the sunroof device for use in the vehicle disclosed in the Patent reference 1, a tooth contact noise that will be explained may occur.

Generally, in the roof apparatus for the vehicle in which the drive cables are used as the drive force transmitting member, a front end surface of each of the guide rails, against which the casing is abutted in order to connect the casing to each of the guide rails, is formed so as to be perpendicular to passages formed at the guide rails for having the driving cables inserted therein.

In the roof apparatus for the vehicle in which the spur tooth rack belts are used as the drive force transmitting member, in case that the front end surface of each of the guide rails, to which the casing is connected, is formed so as to be perpendicular to the passages of the spur tooth rack belts, the front end surface is positioned parallel to each of the spur teeth of the spur tooth rack belts, that is, parallel to the direction in which each of the spur teeth protrudes.

Consequently, in case that the casing is connected to each of the guide rails in an offset manner even slightly in the width direction of the vehicle, and thus a step is formed between an inner wall surface (a surface on which the spur teeth slide) of the casing and an inner wall surface (a surface on which the spur teeth slide) of the each of the guide rails, each of the spur teeth may come into contact with more than one edge portions of the front end surface of each of the guide rails at a time when passing through the connecting portion between the casing and each of the guide rails in order to move from the casing to the guide rails. This may cause a noise (the tooth contact noise).

A need thus exists for a roof apparatus for a vehicle, which is not susceptible to the drawback mentioned above.

SUMMARY

According to an aspect of this disclosure, a roof apparatus for a vehicle includes a pair of guide rails extending in a front/rear direction of the vehicle along side end portions of an opening portion formed on a roof of a vehicle, a movable panel supported by the pair of guide rails and opening and closing the opening portion by moving in the front/rear direction of the vehicle, a housing extending in a width direction of the vehicle along a front end portion of the opening portion, being connected to a front end portion of each of the pair of guide rails and supporting a drive mechanism, a casing at least part of which is constituted by the housing, a first spur tooth rack belt and a second spur tooth rack belt both of which are accommodated in the pair of guide rails and in the casing in a manner that the first spur tooth rack belt and the second spur tooth rack belt slide along the pair of guide rails and along the casing for transmitting a drive force of the drive mechanism to the movable panel. The first spur tooth rack belt includes a plurality of first spur teeth formed on a surface of the first spur tooth rack belt which faces a surface of the second spur tooth rack belt on which a plurality of second spur teeth are formed in a manner that the plurality of first spur teeth and the plurality of second spur teeth protrude in a direction perpendicular to a lengthwise direction of the first spur tooth rack belt and the second spur tooth rack belt, a slope portion constituting part of the casing and being inclined upward toward a rear side of the vehicle is provided forward of each of the pair of guide rails relative to the front/rear direction of the vehicle, a pair of guide portions is provided at each of the guide rails, the guide portions positioned keeping a distance from each other in the width direction of the vehicle for guiding the first spur tooth rack belt and the second spur tooth rack belt respectively in the front/rear direction of the vehicle, each of the pair of guide portions includes a bottom wall portion and a pair of restricting wall positioned at side portions of the bottom wall portion relative to the width direction of the vehicle, and a front end portion of each of the pair of guide rails includes a cutout portion formed by cutting out the bottom wall portion, and the slope portion and each of the pair of guide portions are connected with each other in a manner that the slope portion communicates with each of the pair of guide portions via the cutout portion.

According to another aspect of this disclosure, a roof apparatus for a vehicle includes a pair of guide rails extending in a front/rear direction of the vehicle along side end portions of an opening portion formed on a roof of a vehicle, a movable panel supported by the pair of guide rails and opening and closing the opening portion by moving in the front/rear direction of the vehicle, a housing extending in a width direction of the vehicle along a front end portion of the opening portion, being connected to a front end portion of each of the pair of guide rails and supporting a drive mechanism, a casing at least part of which is constituted by the housing, a first spur tooth rack belt and a second spur tooth rack belt both of which are accommodated in each of the pair of guide rails and in the casing in a manner that the first spur tooth rack belt and the second spur tooth rack belt slide along the pair of guide rails and along the casing for transmitting a drive force of the drive mechanism to the movable panel, the first spur tooth rack belt including a plurality of first spur teeth formed on a surface of the first spur tooth rack belt which faces a surface of the second spur tooth rack belt on which a plurality of second spur teeth are formed in a manner that the plurality of first spur teeth and the plurality of second spur teeth protrude in a direction perpendicular to a lengthwise direction of the first spur tooth rack belt and the second spur tooth rack belt, a slope portion provided forward of each of the pair of guide rails relative to the front/rear direction of the vehicle, the slope portion constituting part of the casing and being inclined upward toward a rear side of the vehicle, a pair of guide portions provided at each of the guide rails, the guide portions positioned keeping a distance from each other in the width direction of the vehicle for guiding the first spur tooth rack belt and the second spur tooth rack belt respectively in the front/rear direction of the vehicle, each of the pair of guide portions including a bottom wall portion and a pair of restricting wall portions positioned at side portions of each of the bottom wall portion in the width direction of the vehicle, a cutout portion formed at a front end portion of each of the pair of guide rails by cutting out the bottom wall portion, and a pair of partition walls formed at a slope configuring portion provided forward of the bottom wall portions of the pair of guide portions in the front/rear direction of the vehicle, each of the pair of partition walls being inclined upward toward the rear side of the vehicle. The slope portion and each of the pair of guide portions are connected with each other in a manner that the slope portion communicates with each of the pair of guide portions via the cutout portion.

DETAILED DESCRIPTION

A first embodiment of a roof apparatus10related to this disclosure will be explained with reference toFIGS. 1 to 13of the attached drawing. In the explanation hereunder, a front/rear direction refers to a forward/rearward direction relative to a traveling direction of the vehicle on which the roof apparatus10is mounted. An upper/lower direction or a vertical direction refers to an upper/lower direction or a vertical direction of the vehicle. A right/left direction or a width direction refers to a right/left direction or a width direction of the vehicle when the vehicle is traveling forward.

As shown in at least one ofFIGS. 1 and 2, the roof apparatus10for the vehicle opens and closes an opening portion12formed on a roof11of a vehicle4by means of a movable panel13in a similar manner used in a known sunroof apparatus.

A pair of guide rails14,15, that is, a left side guide rail14and a right side guide rail15, is provided below left side and right side edge portions of the opening portion12respectively so as to extend in the front/rear direction of the vehicle along the left side and the right side edge portions of the opening portion12. A front housing30(i.e., a housing) is provided below a front edge portion of the opening portion12so as to extend in the width direction of the vehicle along the front edge portion of the opening portion12. The left side and the right side guide rails14,15and the front housing30are fixedly attached to the roof11.

Each of the guide rails14,15includes a uniform cross section that is perpendicular to a longitudinal direction thereof (the front/rear direction of the vehicle). The cross sections of the guide rails14,15are symmetrical to each other in the width direction of the vehicle. The guide rails14,15are formed from an extruded light metal material including aluminum alloy but not limited thereto. Link members5,6each supporting the movable panel13from below are attached to the guide rails14,15respectively so that the link members5,6slide in the front/rear direction of the vehicle and are inclined or tiled upward toward a rear side of the vehicle. Shoe members7,8for sliding the link members5,6in the front/rear direction of the vehicle while inclining the link member5,6upward toward the rear side of the vehicle are attached to the guide rails14,15respectively in a manner that the shoe members7,8slide along the guide rails14,15in the front/rear direction of the vehicle.

Next, a structure of the guide rails14,15will be explained. The structure of the right side guide rail15will be explained and an explanation on the structure of the left side guide rail14will be omitted because the cross sections thereof are symmetrical to each other in the vertical direction of the vehicle as stated above.

As shown inFIG. 6, a left side guide portion16guiding an inner spur tooth rack belt36(i.e., a second spur tooth rack belt), which will be explained below, in the front/rear direction of the vehicle is provided at a left side portion of an inside of the right side guide rail15. The left side guide portion16includes a bottom wall portion17, a pair of restricting wall portions18,19formed at left side and right side portions of the bottom wall portion17respectively in the width direction of the vehicle so as to upwardly protrude in the vertical direction of the vehicle, and an upper wall portion21formed on upper end portions of the restricting wall portions18,19so as to protrude in the width direction of the vehicle and so as to connect the restricting wall portions18,19with each other.

A right side guide portion22guiding an outer spur tooth rack belt35(i.e., a first spur tooth rack belt), which will be explained below (refer toFIGS. 4 and 5), in the front/rear direction of the vehicle is provided at a right side portion of the inside of the right side guide rail15. The right side guide portion22includes a bottom wall portion23, a pair of restricting wall portions24,25formed at left side and right side portions of the bottom wall portion23in the width direction of the vehicle so as to upwardly protrude in the vertical direction of the vehicle, and an upper wall portion26formed on upper end portions of the restricting wall portions24,25so as to protrude in the width direction of the vehicle and so as to connect the restricting wall portions24,25with each other.

A connecting bottom portion27is provided between the left side guide portions16and the right side guide portion22so as to connect the bottom wall portions17and23. The connecting bottom portion27, and the bottom portions27and23positioned at the left and right of the connecting bottom portion27respectively are coplanar to one another.

In the left side guide portion16, the restricting wall portion19, which is positioned closer to the connecting bottom wall portion27than the restricting wall portion18is positioned, is discontinued and separated in two at an intermediate portion thereof in the vertical direction of the vehicle. An upper portion and a lower portion of the restricting wall portion19will be identified as an upper restricting wall portion19U and a lower restricting wall portion19L respectively when necessary.

In the left side guide portion22, the restricting wall portion24, which is positioned closer to the connecting bottom wall portion27than the restricting wall portion25is positioned, is discontinued and separated in two at an intermediate portion thereof in the vertical direction of the vehicle. An upper portion and a lower portion of the restricting wall portion24will be identified as an upper restricting wall portion24U and a lower restricting wall portion24L respectively when necessary.

Because each of the restricting wall portions19,24, which are positioned closer to the connecting bottom wall portion27than the restricting wall portions18,25are positioned, is separated into the two portions as explained above, a communication is established between the inside and an outside of each of the guide portions16,22. Thus, one of the outer spur tooth rack belt35and the inner spur tooth rack belt36, which are accommodated inside the guide portion16,22respectively, is connected to one of the shoe members7or8, which are positioned outside the guide portions16,22respectively.

Representation of the link members5,6is omitted inFIGS. 4 to 6andFIGS. 14 to 16. The front housing30is formed by means of molding a synthetic resin material. As shown inFIG. 7, the left and right end portions of the front housing30in the width direction of the vehicle are connected to front end portions of the guide rails14,15respectively. As shown in at least one ofFIGS. 1 to 3, a gutter portion31for receiving, for example, rain water entering an inside of the roof apparatus10through a front portion of the opening portion12is formed at an upper portion of the front housing30so as to be integral with the front housing30and to extend in the width direction of the vehicle. A drain pipe32is connected to each of the left and right portions of the gutter portion31in the width direction of the vehicle so that, for example, the rain water that drops into the gutter portion31is discharged outside the roof apparatus10through the drain pipes32,32.

As shown inFIG. 12, part of the front housing30constitutes part of each of a pair of casings51,52provided on the left and right sides of the vehicle, which will be explained in details below. As shown inFIG. 8, the outer spur tooth rack belt35and the inner spur tooth rack belt36are arranged substantially in parallel to each other in a longitudinal direction thereof in the casings51,52, the left side guide rail14and the right side guide rail15. The outer spur tooth rack belt35extends in the width direction of the vehicle in the front housing30and extends in the front/rear direction of the vehicle in the guide rails14,15. The outer spur tooth rack belt35is arranged so as to curve at connecting portions between the left side and the right side portions of the front housing30(the casings51,52) and the guide rails14,15respectively. The inner spur rack belt36is positioned rearward of the outer spur tooth rack belt35in the front/rear direction of the vehicle in the front housing30, and is positioned inward of the outer spur tooth rack belt35in the width direction of the vehicle in the guide rails14,15, that is, closer to the lateral center of the vehicle. Due to the above-explained positional relationship, the outer spur tooth rack belt35and the inner spur tooth rack belt36do not intersect with each other at any point when viewed in a plane view. The outer spur tooth rack belt35and the inner spur tooth rack belt36, however, may intersect with each other when viewed in the plane view.

As shown inFIG. 9, the outer spur tooth rack belt35includes plural spur teeth35a(i.e., plural first spur teeth) formed on a surface facing the inner spur tooth rack belt36so that each of the spur teeth35aprotrudes in a direction perpendicular to the longitudinal direction of the outer spur tooth rack belt35, that is, in the vertical direction of the vehicle. In a similar manner, the inner spur tooth rack belt36includes plural spur teeth36a(i.e., plural second spur teeth) formed on a surface facing the outer spur tooth rack belt35so that each of the spur teeth36aprotrudes in a direction perpendicular to the longitudinal direction of the outer spur tooth rack belt36, that is, in the vertical direction of the vehicle. The outer spur tooth rack belt35and the inner spur tooth rack belt36transmit a drive force of the drive mechanism40to the movable panel13.

The outer spur tooth rack belt35and the inner spur tooth rack belt36are formed of a synthetic resin material so as to be flexible. In addition, as shown inFIGS. 4 and 5, each of the outer spur tooth rack belt35and the inner spur tooth rack belt36of this embodiment has a substantially rectangular cross section.

As shown in at least one ofFIGS. 1 to 9and12, a drive mechanism40for driving the outer spur tooth rack belt35and the inner spur tooth rack belt36is supported by the front housing30so as to be positioned in a substantially central portion thereof in the width direction of the vehicle. The drive mechanism40is configured by, for example, an electric motor41fixedly mounted on the front housing30and by a spur gear42driven by the electric motor41to rotate. The spur gear42is disposed between the outer spur tooth rack belt35and the inner spur tooth rack belt36and engages with the spur teeth35aand36a. A reversible motor is used as the spur gear42.

As shown inFIG. 8, in the left side guide rail14, the left side shoe member7is connected to one of the end portions of the outer spur tooth rack belt35, that is, the end portion located on the left side relative to the spur gear42in the width direction of the vehicle. The other one of the end portions of the outer spur tooth rack belt35, that is, the end portion located on the right side relative to the spur gear42refers to a free end portion35fto which no shoe member is connected.

In the right side guide rail15, the right side shoe member8is connected to one of the end portions of the inner spur tooth rack belt36, that is, the end portion located on the right side relative to the spur gear42in the width direction of the vehicle. The other one of the end portions of the inner spur tooth rack belt36, that is, the end portion located on the left side relative to the spur gear42refers to a free end portion36fto which no shoe member is connected.

Consequently, in the right side guide rail15, the shoe member8connected to the inner spur tooth rack belt36is positioned on the left side and the free end portion35fof the outer spur tooth rack belt35is positioned on the right side relative to each other in the width direction of the vehicle. In the left side guide rail14, the shoe member7connected to the outer spur tooth rack belt35is positioned on the left side and the free end portion36fof the inner spur tooth rack belt36is positioned on the right side relative to each other in the width direction of the vehicle. Thus, the shoe members7,8and the free end portions35f,36fare arranged in a similar manner in the left side guide rail14and in the right side guide rail15to each other, more specifically, the shoe members7,8are positioned on the left side and the free end portions35f,36fare positioned on the right relative to each other in the width direction of the vehicle.

Thus, the roof apparatus10for the vehicle includes the basic structure as explained above. Next, characteristic aspects of this embodiment will be explained below. In this embodiment, a connecting structure between the left side and the right side casings51,52and the left side and the right side guide rails14,15are characteristic.

The connecting structure between the left side casing51and the left side guide rail14, and the connecting structure between the right side casing52and the right side guide rail15are identical except that the arrangements of the connecting structures are symmetrical to each other in the width direction of the vehicle. Therefore, the connecting structure between the right side casing52and the right side guide rail15will be explained and the explanation on the connecting structure between the left side casing51and the left side guide rail14will be omitted.

As shown at least one ofFIGS. 4 to 6, a cutout portion45is formed at the front end portion of the right side guide rail15by cutting out, in the front/rear direction of the vehicle, the bottom wall portion17and the lower restricting wall portion19L, both of which configure the left side guide portion16. In addition, a cutout portion46is formed at the front end portion of the right side guide rail15by cutting out the bottom wall portion23and the lower restricting wall portion24L, both of which configure the right side guide portion22.

On the other hand, as shown in at least one ofFIGS. 2,4and5, the casing52is constituted by a casing body53and a casing cover60. A bottom portion of a large part of the casing body53downwardly opens and the opening is covered and closed by the casing cover60from below. Part of the front housing30constitutes the casing body53. Partition walls54,54are formed on at least one of the casing body53and the casing cover60. The partition walls54,54partition a space formed by the casing body53and the casing cover60into passages in which the outer spur tooth rack belt35and the inner spur tooth rack belt36are guided to slide respectively while keeping a distance therebetween.

A rear portion of the casing body53is inclined upward toward the rear side of the vehicle, thereby constituting an upper portion70U of a slope portion70. The casing cover60does not constitute any part of the upper portion70U.

In this embodiment, the casing cover60is formed by means of molding the synthetic resin material of the same type as the material that forms the front housing30. A rear portion of the casing cover60is inclined upward toward the rear side of the vehicle at a substantially similar gradient to that of the inclination of the casing body53. The case cover60constitutes a large portion of a lower portion70L of the slope portion70. A portion of the casing body53is positioned forward of the bottom wall portions17,23of the guide portion16,22in the front/rear direction of the vehicle and, at the same time below the connecting bottom wall portion27in the vertical direction of the vehicle. The above-stated portion of the casing body53is also inclined toward the rear side of the vehicle and constitutes a slope configuring portion55configuring part of the lower portion70L of the slope portion70. A rear end portion of the casing cover60and the slope configuring portion55fill in the cutout portions45,46. The slope configuring portion55is fastened to the connecting bottom wall portion27together with a guide block75, which guides a movement of the link member6, by means of a bolt76and a nut77.

At the slope configuring portion55, the partition walls54,54are formed at left and right end portions of the slope configuring portion55in the width direction of the vehicle, that is, the portions facing the upper restricting wall portions19U,24U of the guide rails15respectively, in a manner that a portion of each of the partition walls54,54upwardly protrudes in the vertical direction of the vehicle. The partition walls54,54perform a function similar to that of the lower restricting wall portions19L,24L. The partition walls54,54are also gradually inclined upward toward the rear side of the vehicle. Rear end portions of the partition walls54,54are connected to the front end portions of the lower restricting wall portions19L,24L of the guide rail15respectively. An interior space (i.e., the passages) of each of the slope portions70,70communicates with an interior space of the left side and the right side guide portions16,22via the cutout portions45,46.

A recess portion56which constitutes part of the casing body53and is positioned lower than the other portion of the slope configuring portion55is provided under the cutout portion45,46in the vertical direction of the vehicle so as to be positioned forward of the slope configuring portion55in the front/rear direction of the vehicle. A recess portion (not shown) similar to the recess portion56is provided on the casing body53at an end portion thereof (refer toFIG. 13) closer to the drive mechanism40. On each of the casing bodies53,53provided at left and right sides of the vehicle, a boss57is formed at plural points so as to downwardly protrude.

On the other hand, each of the left side and the right side casing covers60,60is formed into a curved flat plate. As shown at least one ofFIGS. 4 and 13, a locking protrusion61(i.e., the rear end portion) provided at each end portion of the left side and the right side casing covers60,60. The locking protrusion61is inserted into the recess portion56of the slope configuring portion55so as to engage therewith and is stopped by the recess portion56. An upper surface of the locking protrusion61is inclined upward toward the rear side of the vehicle. On each of the casing covers60,60provided at the left and right sides of the vehicle, a hole62is formed at plural points corresponding to the plural points at which the boss57is formed so as to receive therein the corresponding boss57.

The casing cover60is fastened to the casing body53in the above-explained manner, and thus the passages in which the outer spur tooth rack belt35and the inner spur tooth rack belt36slide are formed. In addition, the slope portion70is provided forward of each of the guide rails14,15so as to be inclined upward toward the rear side.

In addition, as shown in at least one ofFIGS. 10 and 11, a pair of vertical walls58,58is provide at the rear end portion of the casing body53so as to be positioned on the left side and the right side in the width direction of the vehicle while keeping a distance therebetween. In a state where the slope portion70is connected to the right side guide rail15, the front portion of the guide rail15comes into contact with or comes close to the pair of vertical walls58,58. Lugs59,59each formed into an elongated shape are provided at lower end portions of the vertical walls58,58so as to protrude in the rear direction of the vehicle. A clearance D having a substantially triangle shape when viewed from the width direction of the vehicle is formed between an upper surface of each of the outer spur tooth rack belt35and the inner spur tooth rack belt36both of which are inclined along the slope portion70, and each of the upper wall portions21,26of the guide portion16,22.

Thus, the roof apparatus10for the vehicle of this embodiment includes the above-explained structure. The outer spur tooth rack belt35and the inner spur tooth rack belt36move in opposite directions with each other along the left side and the right side guide rails14,15, and along the passages formed by the casing body53and the casing cover60when the electric motor41of the drive mechanism40drives the spur gear42in the normal direction and the reverse direction. The outer spur tooth rack belt35and the inner spur tooth rack belt36move in the front/rear direction of the vehicle in the left side and the right side guide rails14,15. As the outer spur tooth rack belt35and the inner spur tooth rack belt36move in the front/rear direction of the vehicle, the shoe members7,8are driven to move, and the movable panel13moves so as to open and close the opening portion12.

For example, in case that the spur gear42is driven to rotate in the counterclockwise direction as indicated by the arrow inFIG. 8, the outer spur tooth rack belt35moves in the rear direction of the vehicle in the left side guide rail14and moves in the front direction of the vehicle in the right side guide rail15. The inner spur tooth rack belt36moves in the rear direction of the vehicle in the right side guide rail14.

As the outer spur tooth rack belt35moves in the rear direction of the vehicle in the left side guide rail14, the shoe member7also moves in the rear direction. As the inner spur tooth rack belt36moves in the rear direction of the vehicle in the right side guide rail15, the shoe member8also moves in the rear direction. As the shoe members7,8move in the rear direction of the vehicle, the movable panel13moves in the rear direction, and thus the opening portion12is released.

In case that the spur gear42is driven to rotate in the clockwise direction inFIG. 8, the outer spur tooth rack belt35and the inner spur tooth rack belt36move in the directions reverse to the above-explained directions, and thus the movable panel13moves in the front direction of the vehicle so as to close the opening portion12.

When the spur teeth35aand the spur teeth36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36pass through the slope portions70,70provided on the left side and the right side casings51,52in the rear direction of the vehicle while causing the opening portion12to open, the spur tooth35aand the spur tooth36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36are positioned perpendicular to a longitudinal direction of the slope portion70as shown inFIG. 11. InFIG. 11, only representative teeth from among the plural teeth35a,36aare indicated. Because the slope portion70is inclined upward toward the rear side of the vehicle, the teeth35a,36aare also inclined so that an upper portion of each of the spur teeth35a,36ais positioned forward and a lower portion thereof is positioned rearward in the front/rear direction of the vehicle as indicated by (A) inFIG. 11.

On the other hand, in a state where the slope portions70,70of the left side and the right side casings51,52are connected to the left side and the right side guide rails14,15respectively, the partition walls54,54of the left side and the right side casings51,52are abutted and connected to a front end faces of each of the restricting wall portions19,24. The front end faces of the restricting wall portions19,24are perpendicular (in this case, vertical) to the passages in which the outer spur tooth rack belt35and the inner spur tooth rack belt36slide.

Consequently, when the spur teeth35a,36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36move from the slope portions70,70to the left and the right guide rails14,15, the spur teeth35a,36aare guided by the slope portion70to move diagonally upwardly from a position, which is in the casing51,52and lower than the left side and the right side guide rails14,15in the vertical direction of the vehicle. At this time, the spur teeth35a,36aare inclined in a manner that the upper portions of the spur teeth35a,36aare positioned forward and the lower portions thereof are positioned rearward in the front/rear direction of the vehicle.

Thus, the spur teeth35a,36apass through the cutout portions45,46formed on the front end portion of the left and the right guide rails14,15while maintaining the tilted state. At this time, in the left side and the right side guide rails14,15the spur tooth35aand the spur tooth36acome into contact with the restricting wall portions19,24which are formed at the left and right side portions of the bottom wall portion17respectively, while maintaining the tilted state as indicated by (B) inFIG. 11. More specifically, the spur tooth35aand the spur tooth36afirst come into contact with the upper restricting wall portions19U,24U respectively while maintaining the tilted state.

Therefore, unlike in the state where the spur teeth35a,36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36are parallel to the front end surfaces of the left and the right guide rails14,15(i.e., the known sunroof apparatus), each of the spur teeth36aof the inner spur tooth rack belt36does not come into contact with an edge portion, that is, a lower edge portion, of the front end face of the upper restricting wall portions19U and with an edge portion, that is, an upper end portion, of the front end face of the lower restricting wall portions19L at the same time. As a result, an abnormal noise (a tooth contact noise) caused by the spur teeth36acoming into contact with the edge portion of the front end face of the upper restricting wall portion19U and the edge portion of the front end face of the lower restricting wall portions19L at the same time, may be controlled. In a same manner, the spur teeth35aof the outer spur tooth rack belt35does not come into contact with an edge portion, that is, a lower edge portion, of the front end face of the upper restricting wall portions24U and with an edge portion, that is, an upper edge portion, of the front end face of the lower restricting wall portions24L at the same time. As a result, the tooth contact noise caused by the spur tooth35acoming into contact with the edge portion of the front end face of the upper restricting wall portion24U and the edge portion of the front end face of the lower restricting wall portions24L at the same time, may be controlled.

As shown in at least one of theFIGS. 4 to 6and11, after passing through the position indicated by (B) in theFIG. 11, the spur teeth35a,36apass through the slope configuring portion55of the casing53positioned forward of the bottom wall portions17,23of the guide portion16,22in the front/rear direction of the vehicle. The slope configuring portion55functions as part of the lower portion70L of the slope portion70. Thus, the spur teeth35a,36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36pass through the slope configuring portion55in the tilted state when moving from the slope portion70to the guide rails14,15. However, a degree of inclination of the spur teeth35a,36abecomes gradually smaller as the spur teeth35a,36amove in the rear direction of the vehicle, that is, the spur teeth35a,36agradually become vertically positioned.

The spur tooth35aas a whole and the spurt tooth36aas a whole enter the guide portions16,22after passing through the cutout portions45,46respectively. At this time, as indicated by (C) inFIG. 11, the spur teeth35a,36acome into contact with the front end faces of the lower restricting portions19L,24L of the guide rail14,15. However, the generation of the abnormal noise (the tooth contact noise) may be controlled because the upper portions of the spur teeth35a,36aare supported by the upper restricting wall portions19U,24U respectively.

The outer spur tooth rack belt35and the inner spur tooth rack belt36, which entered the guide portions16,22of the guide rails14,15respectively, are guided by the bottom wall portions17,23and by the restricting wall portions18,19,24,25so as to move in the rear direction of the vehicle. At this time, the outer spur tooth rack belt35and the inner spur tooth rack belt36in the guide portions16,22are supported from below by the bottom wall portions17,23and restricted by the restricting wall portions18,19,24,25from moving in the width direction of the vehicle.

As explained above, according to the roof apparatus10for the vehicle of this embodiment, the following effects and advantages may be achieved. The slope portion70which constitutes part of each of the casing51,52and which is inclined upward toward the rear side of the vehicle is provided forward of each of the left side and the right side guide rails14,15in the front/rear direction of the vehicle. The pair of guide portions16,22is provided at each of the guide rails14,15so as to be positioned on the left side and the right side in the width direction of the vehicle while keeping a distance therebetween for guiding the outer spur tooth rack belt35and the inner spur tooth rack belt36respectively in the front/rear direction of the vehicle. The left side guide portion16includes the bottom wall portions17and the restricting wall portion18,19formed at the left side and the right side portions of the bottom wall portion17respectively in the width direction of the vehicle. The right side guide portion22includes the bottom wall portions23and the restricting wall portions24,25formed at the left side and the right side portions of the bottom wall portion23respectively in the width direction of the vehicle. The cutout portions45,46are formed at the front end portion of each of the guide rails14,15by cutting out the bottom wall portions17,23of the guide portions16,22. The slope portions70,70communicate with the guide portion16,22via the cutout portions45,46respectively (refer toFIGS. 4 and 6).

Thus, the spur teeth35a,36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36become inclined while passing through the slope portion70. Then, the spur teeth35a,36aenter the inside of the guide rails portions16,22via the cutout portions45,46formed at the front end portions of the guide rails14,15while maintaining the tilted state. When entering the inside of the guide rails portions16,22, the spur teeth35a,36acome into contact with the restricting wall portions19,24of the guide portion16,22of the guide rails14,15in the tilted state.

As a result, even in case that the casings51,52are connected to the guide rails14,15in a misaligned manner relative to the guide rails14,15in the width direction of the vehicle, and therefore inner wall surfaces of the slope portions70,70and inner wall surfaces of the guide rails14,15include a step formed therebetween, the generation of the tooth contact noise that attributes to that the spur teeth35a,36acome into contact with the edge portions of the front end faces of the upper restricting wall portions19U,24U and the edge portion of the front end faces of the lower restricting wall portions19L,24L at the same time may be controlled.

Thus, it is not necessary from a viewpoint of the tooth contact noise to connect the casings51,52to the guide rails14,15with a high precision so that no step is formed between the inner wall surfaces of the slope portions70,70and the inner wall surfaces of the guide rails14,15.

Each of the casings51,52is constituted by the casing body53whose bottom portion downwardly opens and the casing cover60closing the opening of the casing body53from below (refer toFIG. 2). Thus, the passages in which the outer spur tooth rack belt35and the inner spur tooth rack belt36are inserted are formed between the casing body53and the casing cover60in the vertical direction of the vehicle in a simple way. In addition, the slope portions70,70are readily formed by the casing body53and the casing cover60so as to be positioned forward of the guide rails14,15respectively in a manner that the slope portion70is inclined upward toward the rear side of the vehicle.

The slope configuring portion55configuring part of the lower portion70L of the slope portion70is provided at the casing body53at a position forward of the bottom wall portions17,23of the guide portion16,22. The recess portion56is provided at a position forward of the slope configuring portion55. The locking protrusion61provided at the rear end portion of the casing cover60engages with and is stopped by the recess portion56(refer toFIGS. 2 and 4).

According to the roof apparatus10for the vehicle of this embodiment, each of the casings51,52is constituted by the casing53and the casing cover60, however, the casing cover60is assembled to the casing body53while being positioned relative to the casing body53by having the locking protrusion61engaged with and stopped by the recess56as explained above.

The lug59is provided at the lower end portion of each of the pair of vertical wall portions58,58provided at the rear end of the casing bodies53so that the lug59protrudes in the rear direction of the vehicle. Each of the lugs59,59is inserted into the clearance D having the substantially triangle shape when viewed from the width direction of the vehicle. The clearance D is formed between the outer and the inner spur tooth rack belts35,36inclined by means of the slope portions70,70and the upper wall portions21,26of the guide portions16,22(refer toFIGS. 10 and 11).

Thus, the lugs59,59restrict the slope portions70,70(the casing bodies53,53) from moving relative to the guide rails14,15in the width direction of the vehicle. In addition, in the slope portions70,70, the outer and the inner spur tooth rack belts35,36are restricted by the lugs59,59from moving, that is, flapping in the upper direction of the vehicle.

Each of the guide rails14,15is provided with the pair of guide portion16,22. In one of the guide portions16and22provided at the left side guide rail14, the end portion of, for example, the outer spur tooth rack belt35to which the shoe member7is connected is guided. In the other one of the guide portions16and22, the free end36fof the inner spur tooth rack belt36is guided. In a similar manner to that explained above, in one of the guide portions16and22provided at the right side guide rail15, the end portion of, for example, the inner spur tooth rack belt36to which the shoe member8is connected is guided. In the other one of the guide portions16and22, the free end35fof the outer spur tooth rack belt35is guided.

Consequently, the outer spur tooth rack belt35and the inner spur tooth rack belt36do not intersect with each other at any point when viewed in a plane view. In addition, one of the spur tooth rack belts35and36is set to be the outer spur tooth rack belt35, and the other of the spur tooth belts35and36is set to be the inner spur tooth rack belt36that is positioned inward of the outer spur tooth rack belt35in the width direction of the vehicle and actuated to move.

Thus, the shoe members7,8and the free end portions35f,36fare arranged in a similar manner in the left side guide rail14and in the right side guide rail15to each other, more specifically, the shoe members7,8are positioned on the left side and the free end portions35f,36fare positioned on the right side relative to each other.

The casing cover60is made from the synthetic resin material of the same type as the material that forms the front housing30. Thus, the casing cover60and the front housing30may be formed in one molding die at the same time, which may reduce a cost of the molding die and a processing cost.

Variations or changes may be made to the above-explained first embodiment as follows. Second, third and fourth embodiments of a roof apparatus related to this disclosure will be explained with reference to illustrations ofFIGS. 14 to 16of the attached drawings. At each of the front end portions of the guide rails14,15, the connecting bottom wall portion27is not directly involved in the movement of the outer spur tooth rack belt35and the inner spur tooth rack belt36in the front/rear direction of the vehicle. Therefore, at the front end portion of each of the guide rails14,15, an intermediate cutout portion47may be formed at the connecting bottom wall portion27by cutting out, in the front/rear direction of the vehicle, the connecting bottom wall portion27(the second embodiment).

In order to form the intermediate cutout portion47at the connecting bottom wall portion27in addition to the cutout portions45,46, the entire bottom portion of the front end portion of the each of the guide rails14,15needs to be cut out. In this case, a process for forming the cutout portions is easier compared to the case where only the cutout portions45,46are formed by cutting out the front end portion of the bottom portion of the bottom wall portions17,23.

Further, in case that the cutout portions45,46and the intermediate cutout portion47are formed, the configuration of the slope portion70of each of the casings51,52may be simplified compared to the case where only the cutout portions45,46are formed by cutting out the front end portions of the bottom wall portions17,23.

In the first embodiment, the partition wall54is formed on the slope configuring portion55of each of the casing bodies53,53(refer toFIGS. 4 and 5). The partition wall54may be, however, provided on each of the casing covers60,60as shown inFIG. 15(the third embodiment). Alternatively, the partition walls54,54may be formed on the connecting bottom wall portion27at end portions thereof in the width direction of the vehicle while keeping a distance between the partition walls54,54in the width direction of the vehicle (the fourth embodiment).

The restricting wall portions19,24, which are positioned closer to the connecting bottom wall portion27than the restricting wall portions18,25are positioned, is separated into the two portions in an area where the shoe members7,8move in the front/rear direction of the vehicle. In this area, the communication needs to be established between the inside and the outside of each of the guide portions16,22so that the outer spur tooth rack belt35and the inner spur tooth rack belt36accommodated in the guide portions16,22respectively are connected to the shoe members7,8positioned outside the guide portions16,22respectively.

On the other hand, the slope portion70is positioned to be away toward the front direction of the vehicle from the ranges of movement of the shoe members7,8. Thus, at the slope portion70, the upper restricting wall portion19U and the lower restricting wall portion19L may be connected with each other so as to form one restricting wall, and the upper restricting wall portion24U and the lower restricting wall portion24L may be connected with each other so as to form one restricting wall.

The casing cover60may be made from a synthetic resin material which is different from that forms the casing body53(the front housing30) or may be made from other material than the synthetic resin, including but not limited to a metal.

In the first embodiment, the slope configuring portion55is formed to be part of the casing body53(front housing30), however, the slope configuring portion55may be integrally formed to be part of casing cover60.

The entire casing51and the entire casing52may be constituted by the front housing30. Further, the first, second, third and fourth embodiments are adapted to be used in the roof apparatus10for the vehicle, where the gutter portion31is formed separately from the housing30.

According to the embodiments, the roof apparatus10for the vehicle includes the pair of guide rails14,15extending in the front/rear direction of the vehicle along the side end portions of the opening portion12formed on the roof11of the vehicle4, the movable panel13supported by the pair of guide rails14,15and opening and closing the opening portion12by moving in the front/rear direction of the vehicle, the front housing30extending in the width direction of the vehicle along the front end portion of the opening portion12, being connected to the front end portion of each of the pair of guide rails14,15and supporting the drive mechanism40, the casing51,52at least part of which is constituted by the front housing30, the outer spur tooth rack belt35and the inner spur tooth rack belt36both of which are accommodated in the pair of guide rails14,15and in the casing51,52in a manner that the outer spur tooth rack belt35and the inner spur tooth rack belt36slide along the pair of guide rails14,15and along the casing51,52for transmitting the drive force of the drive mechanism40to the movable panel13. The outer spur tooth rack belt35includes the plural spur teeth35aformed on the surface of the outer spur tooth rack belt35which faces the surface of the inner spur tooth rack belt36on which the plural spur teeth36aare formed in a manner that the plural spur teeth35aand the plural spur teeth36aprotrude in the direction perpendicular to the lengthwise direction of the outer spur tooth rack belt35and the inner spur tooth rack belt36, the slope portion70constituting part of the casing51,52and being inclined upward toward the rear side of the vehicle is provided forward of each of the pair of guide rails14,15relative to the front/rear direction of the vehicle, the pair of guide portions16,22is provided at each of the guide rails14,15, the guide portions16,22positioned keeping the distance from each other in the width direction of the vehicle for guiding the outer spur tooth rack belt35and the inner spur tooth rack belt36respectively in the front/rear direction of the vehicle, each of the pair of guide portions16,22includes the bottom wall portion17,23and the pair of restricting wall portions18,19,24,25positioned at the side portions of the bottom wall portion17,23relative to the width direction of the vehicle, and the front end portion of each of the pair of guide rails14,15includes the cutout portion45,46formed by cutting out the bottom wall portion17,23, and the slope portion70and each of the pair of guide portions16,22are connected with each other in a manner that the slope portion70communicates with each of the pair of guide portions16,22via the cutout portion45,46.

According to the above-described structure, when the spur teeth35a,36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36move from the slope portions70,70to the left and the right guide rails14,15, the spur teeth35a,36aare guided by the slope portion70to move gradually diagonally upward from the position, which is in the casing51,52and lower than the left side and the right side guide rails14,15in the vertical direction of the vehicle. At this time, the spur teeth35a,36aare inclined in a manner that the upper portions of the spur teeth35a,36aare positioned forward and the lower portions thereof are positioned rearward in the front/rear direction of the vehicle. Thus, the spur teeth35a,36aenter the inside of the guide rails portions16,22via the cutout portions45,46formed at the front end portions of the guide rails14,15while maintaining the tilted state. When entering the inside of the guide rails portions16,22, the spur teeth35a,36acome into contact with the restricting wall portions19,24of the guide portion16,22of the guide rails14,15in the tilted state, and thus the generation of the tooth contact noise is controlled.

According to the embodiments, each of the pair of guide rails14,15includes the connecting bottom wall portion27provided between the pair of guide portions16,22for connecting the bottom wall portions17,23with each other and the front end portion of each of the pair of guide rails14,15includes the intermediate cutout portion47formed by cutting out the connecting bottom wall portion27.

According to the above-described structure, at each of the front end portions of the guide rails14,15, the connecting bottom wall portion27is not directly involved in the movements of the outer spur tooth rack belt35and the inner spur tooth rack belt36in the front/rear direction of the vehicle. Therefore, the intermediate cutout portion47may be formed at the connecting bottom wall portion27by cutting out, in the front/rear direction of the vehicle, the front end portion of the connecting bottom wall portion27. In order to form the intermediate cutout portion47at the connecting bottom wall portion27in addition to the cutout portions45,46, the entire bottom portion of the front end portion of the each of the guide rails14,15needs to be cut out. In this case, the process for forming the cutout portions is easier compared to the case where only the cutout portions45,46are formed by cutting out the front end portions of the bottom wall portions17,23. Further, the configuration of the slope portion70of each of the casings51,52may be simplified.

According to the embodiments, the casing51,52includes the casing body53whose bottom portion downwardly opens and the casing cover60closing the casing body53from below, and the passages into which the outer spur tooth rack belt35and the inner spur tooth rack belt36are inserted are formed between the casing body53and the casing cover60. The slope portion70includes the upper portion70U and the lower portion70L, and the upper portion70L is constituted by part of the casing body53and at least part of the lower portion70L is constituted by part of the casing cover60.

According to the above-described structure, the casing52is constituted by the casing body53and the casing cover60. Thus, the passages in which the outer spur tooth rack belt35and the inner spur tooth rack belt36are inserted, and the slope portion70are formed in a simple way.

According to the embodiments, the casing body53includes the slope configuring portion55provided forward of the bottom wall portions17,23of the pair of guide portions16,22relative to the front/rear direction of the vehicle and constituting part of the lower portion70L of the slope portion70, and the recessed portion56provided forward of the slope configuring portion55in the front/rear direction of the vehicle, and the locking protrusion61of the casing cover60engages with and is stopped by the recessed portion56.

According to the above-described structure, the slope configuring portion55, which is positioned forward of the bottom wall portions17,23of the guide portion16,22relative to the front/rear direction of the vehicle, functions as part of the lower portion70L of the slope portion70. Thus, the spur teeth35a,36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36pass through the slope configuring portion55in the tilted state when moving from the slope portion70to the guide rails14,15.

According to the above-described structure, each of the casings51,52is constituted by the casing53and the casing cover60, however, the casing cover60is assembled to the casing body53while being positioned relative to the casing body53by having the locking protrusion61engaged with and stopped by the recess56as explained above.

According to the first embodiment, the slope configuring portion55includes the pair of partition walls54,54.

According to the above-described structure, the outer spur tooth rack belt35and the inner spur tooth rack belt36are restricted by the partition walls54,54from moving in the width direction of the vehicle.

According to the embodiments, the roof apparatus10for the vehicle includes the pair of guide rails14,15extending in the front/rear direction of the vehicle along the side end portions of the opening portion12formed on the roof11of the vehicle4, the movable panel13supported by the pair of guide rails14,15and opening and closing the opening portion12by moving in the front/rear direction of the vehicle, the front housing30extending in the width direction of the vehicle along the front end portion of the opening portion12, being connected to the front end portion of each of the pair of guide rails14,15and supporting the drive mechanism40, the casing51,52at least part of which is constituted by the front housing30, the outer spur tooth rack belt35and the inner spur tooth rack belt36both of which are accommodated in each of the pair of guide rails14,15and in the casing51,52in a manner that the outer spur tooth rack belt35and the inner spur tooth rack belt36slide along the pair of guide rails14,15and along the casing51,52for transmitting the drive force of the drive mechanism40to the movable panel13, the outer spur tooth rack belt35including the spur teeth35aformed on the surface of the outer spur tooth rack belt35which faces the surface of the inner spur tooth rack belt36on which the spur teeth36aare formed in a manner that the spur teeth35aand the spur teeth366protrude in the direction perpendicular to the lengthwise direction of the outer spur tooth rack belt35and the inner spur tooth rack belt36, the slope portion70provided forward of each of the pair of guide rails14,15relative to the front/rear direction of the vehicle, the slope portion70constituting part of the casing51,52and being inclined upward toward the rear side of the vehicle, the pair of guide portions16,22provided at each of the guide rails14,15, the guide portions16,22positioned keeping the distance from each other in the width direction of the vehicle for guiding the outer spur tooth rack belt35and the inner spur tooth rack belt36respectively in the front/rear direction of the vehicle, each of the pair of guide portions16,22including the bottom wall portion17,23and the pair of restricting wall portions18,19,24,25positioned at the side portions of each of the bottom wall portion17,23in the width direction of the vehicle, the cutout portion45,46formed at the front end portion of each of the pair of guide rails14,15by cutting out the bottom wall portion17,23, and the pair of partition walls54,54formed at the slope configuring portion55provided forward of the bottom wall portions17,23of the pair of guide portions16,22in the front/rear direction of the vehicle, each of the pair of partition walls54,54being inclined upward toward the rear side of the vehicle. The slope portion70and each of the pair of guide portions16,22are connected with each other in a manner that the slope portion70communicates with each of the pair of guide portions16,22via the cutout portion45,46.

According to the embodiments, the roof apparatus10for the vehicle, which controls the tooth contact noise generated when the spur teeth35aand the spur teeth36aof the outer spur tooth rack belt35and the inner spur tooth rack belt36pass through the connecting portion between the casing and each of the pair of guide rails.