VEHICLE ROOF STRUCTURE AND METHOD FOR MANUFACTURING VEHICLE ROOF STRUCTURE

A vehicle roof structure includes a frame and a deflector device. The frame defines an opening portion opened and closed by a movable panel. The deflector device includes a deflector and a torsion spring. The frame includes a first spring support portion supporting a first arm of the torsion spring in such a way as to be movable in a front-rear direction. The deflector includes a second spring support portion supporting a coil portion and a second arm of the torsion spring, and a holding portion that can hold the first arm. The first spring support portion includes a guide surface. Under a condition that the holding portion holds the first arm, when the deflector rotates toward a retracted position, the first arm slides on the guide surface, and is thereby shifted to a state of being supported by the first spring support portion.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2022-133939, filed on Aug. 25, 2022 and Japanese Patent Application No. 2023-104345, filed on Jun. 26, 2023, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

This disclosure generally relates to a vehicle roof structure and a method for manufacturing a vehicle roof structure.

BACKGROUND DISCUSSION

JP2012-106743A (Reference1) describes a vehicle roof structure that includes a roof including an opening portion, a movable panel opening and closing the opening portion, and a deflector device reducing a wind noise being generated when a vehicle travels in a state where the opening portion is opened. The deflector device includes a deflector supported by the roof in such a way as to be swingable around an axis extending in a width direction, and a torsion spring including one arm fixed to the roof and another arm fixed to the deflector. When the movable panel opens the opening portion, the deflector device deploys, by restoration force of the torsion spring, the deflector to a position where a wind noise can be reduced.

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

SUMMARY

A vehicle roof structure according to one aspect of this disclosure includes a frame and a deflector device. The frame defines an opening portion that is opened and closed by a movable panel. The deflector device includes a deflector and a torsion spring. The deflector is supported in such a way as to be rotatable around an axis extending in a width direction, and rotates between a retracted position and a deployed position that is more displaced upward relative to the opening portion than the retracted position. The torsion spring includes a coil portion, a first arm that extends from a first end of the coil portion, and a second arm that extends from a second end of the coil portion, and is elastically compressed and deformed as the deflector is displaced from the deployed position toward the retracted position. The frame includes a first spring support portion that supports the first arm of the torsion spring in such a way as to be movable in a front-rear direction. The deflector includes a second spring support portion that supports the coil portion and the second arm of the torsion spring, and a holding portion that can hold the first arm. The first spring support portion includes a guide surface on which the first arm is slidable. Under a condition that the holding portion holds the first arm, when the deflector rotates toward the retracted position, the first arm slides on the guide surface, and is thereby shifted to a state of being supported by the first spring support portion.

A method for manufacturing a vehicle roof structure according to one aspect of this disclosure includes a spring temporary assembly step and a spring attachment step. The spring temporary assembly step includes causing a second spring support portion to support a coil portion and a second arm, and causing a holding portion to hold a first arm. The spring attachment step includes, after the spring temporary assembly step, rotating a deflector toward a retracted position, thereby causing the first arm to slide on a guide surface, and causing the first arm to be supported by a first spring support portion.

DETAILED DESCRIPTION

The following describes one embodiment of a vehicle roof structure (hereinafter, referred to as “roof structure”) and a manufacturing method therefor. In the following description, a width direction, a front-rear direction, and an up-down direction of the roof structure are simply referred to as a width direction, a front-rear direction, and an up-down direction.

<Configuration of Present Embodiment>

As illustrated inFIG.1, the roof structure10includes a frame11, a fixed panel12, a movable panel13, and a deflector device14. The roof structure10includes an opening portion15. The roof structure10has a structure symmetrical with respect to the width direction. In the following description, when there are two symmetrical configurations on a right side and on a left side in the width direction, the configuration on the right side will be described.

As illustrated inFIG.1andFIG.2, the frame11includes two side frames20extending in the front-rear direction while being spaced from each other in the width direction, and a front frame30coupling front ends of the two side frames20to each other. The frame11defines the opening portion15by the two side frames20and the front frame30. Although not illustrated in the drawings, the frame11may include a rear frame that couples rear ends of the two side frames20to each other, or may include a center frame that couples, to each other, intermediate portions of the two side frames20in the front-rear direction.

As illustrated inFIG.3, the side frame20includes a guide rail21extending in the front-rear direction, and a deflector support portion22supporting constituent components of the deflector device14. The guide rail21may be made of, for example, a metal material such as aluminum. The deflector support portion22has a substantially rectangular-parallelepiped shape. The deflector support portion22may be a resin molded product, for example. The deflector support portion22includes a support shaft23whose axial direction is the width direction. The support shaft23has a cylindrical shape. As illustrated inFIG.2, the deflector support portion22is fixed near a front end of the guide rail21.

As illustrated inFIG.2andFIG.3, the front frame30includes a housing31and two first spring support portions100. In the present embodiment, the front frame30may be a resin molded product. In this regard, the housing31and the two first spring support portions100are preferably molded integrally with each other.

A longitudinal direction of the housing31is the width direction. In a plan view from an upper side, both end portions of the housing31in the width direction are curved rearward. The housing31holds constituent components for driving the below-described movable panel13. Both end portions of the housing31in the width direction are connected to the respective front ends of the two guide rails21. The housing31includes an accommodation portion31a. The accommodation portion31ais a space recessed downward. In a plan view from an upper side, a longitudinal direction and a lateral direction of the accommodation portion31aare the width direction and the front-rear direction, respectively. The housing31is positioned on a front side of the two first spring support portions100.

The two first spring support portions100are positioned on both sides in the housing31in the width direction. As illustrated inFIG.4, the first spring support portion100includes a front wall110and a side wall120that extend upward from the housing31, and a first upper wall130, a second upper wall140, and a lower wall150that are positioned on a rear side of the front wall110. The first spring support portion100includes a communication groove161that is a groove between the first upper wall130and the second upper wall140, and a slide space162that is a space between the lower wall150and each of the first upper wall130and the second upper wall140.

A thickness direction of the front wall110is the front-rear direction, and a thickness direction of the side walls120is the width direction. The side wall120is positioned on an outer side of the front wall110, the first upper wall130, the second upper wall140, and the lower wall150in the width direction. The front wall110defines a rear portion of the accommodation portion31a. In other words, the front wall110extends upward from a bottom surface of the accommodation portion31a. A gap exists between the side wall120and each of the first upper wall130, the second upper wall140, and the lower wall150. This gap is connected to the communication groove161and the slide space162in the width direction.

The first upper wall130has a plate shape whose thickness direction is the up-down direction. The first upper wall130extends rearward from an upper end of the front wall110. The first upper wall130includes a first upper surface131facing upward and a first rear surface132facing rearward. Both the first upper surface131and the first rear surface132have flat-surface shapes. The first upper wall130corresponds to “upper wall”, and the first upper surface131corresponds to “guide surface”.

The second upper wall140has a plate shape whose thickness direction is the up-down direction. The second upper wall140extends rearward while being spaced from the first upper wall130in the front-rear direction. The second upper wall140includes a second upper surface141facing upward and a second front surface142facing forward. The second upper surface141is positioned on an upper side of the first upper surface131in the up-down direction. In this regard, it can be said that the second upper wall140extends up to a position on an upper side of the first upper wall130. The second front surface142includes a second front surface142athat extends downward from a front end of the second upper surface141, a second front surface142bthat extends downward from a lower end of the second front surface142awhile being shifted forward, and a second front surface142cthat extends downward from a lower end of the second front surface142b. In the up-down direction, an upper end of the second front surface142bis positioned at the substantially same height as an upper end of the first rear surface132, and a lower end of the second front surface142cis positioned at the substantially same height as a lower end of the first rear surface132. In this regard, it can be said that the communication groove161is positioned between the first rear surface132and the second front surface142. Although the first upper wall130and the second upper wall140are illustrated inFIG.4in such a way as to appear to be separated from each other, the first upper wall130and the second upper wall140are connected to each other at a position shifted in the width direction from the section illustrated inFIG.4.

Similarly to the first upper wall130and the second upper wall140, the lower wall150has a plate shape whose thickness direction is the up-down direction. The lower wall150extends rearward from the front wall110, on a lower side of the first upper wall130and the second upper wall140. In other words, the lower wall150faces the first upper wall130and the second upper wall140in the up-down direction. A length of the lower wall150in the front-rear direction is longer than a length of the first upper wall130in the front-rear direction. The lower wall150has a slide surface151facing upward. The slide surface151has a flat-surface shape. The slide surface151faces the slide space162. The slide space162is connected to the communication groove161.

As illustrated inFIG.1, the fixed panel12is a panel that covers an area on a rear side of the opening15. The fixed panel12is a non-displaceable panel, differently from the movable panel13described next. The fixed panel12is fixed to the frame11by using fastening components such as bolts or rivets.

As illustrated inFIG.1, the movable panel13is a panel that opens and closes the opening portion15of the roof structure10. The movable panel13has a size depending on the opening portion15of the roof structure10. The movable panel13is operated between a fully opening position of fully opening the opening portion15and a fully closing position of fully closing the opening portion15, by an un-illustrated drive unit. For example, such a drive unit may be configured in such a way as to include an electric motor and a power transmission mechanism that converts rotational movement of an output shaft of the electric motor into forward and rearward movement of the movable panel13.

In the present embodiment, an opening direction of the movable panel13is a rearward direction, and a closing direction of the movable panel13is a frontward direction. The movable panel13at the fully opening position may be positioned on an upper side of the fixed panel12, or may be positioned on a lower side of the fixed panel12. In other words, the movable panel13may be an outer slide type movable panel13or an inner slide type movable panel13.

As illustrated inFIG.3andFIG.5, the deflector device14includes a deflector40and a torsion spring50.

The deflector40includes a deflector body41, two deflector arms42, and two second spring support portions200. The deflector40may be a resin molded product, for example. The deflector40may be integrally molded, or may be configured by combining a plurality of components.

The deflector body41has a rod shape whose longitudinal direction is the width direction. A length of the deflector body41in the width direction is equivalent to a length of the opening portion15in the width direction. Preferably, the deflector body41is curved moderately relative to the width direction.

The two deflector arms42each have a shape of an elongated plate. The two deflector arms42extend from both end portions of the width direction in the deflector body41. The deflector arm42includes a support hole43that engages with the support shaft23of the deflector support portion22. Assuming that in a longitudinal direction of the deflector arm42, an end portion connected to the deflector body41is a distal end, and an end portion opposite to the distal end is a proximal end, the support hole43is positioned at the proximal end of the deflector arm42.

The two second spring support portions200are positioned on both sides in the deflector body41in the width direction. The second spring support portion200includes a first side wall210and a second side wall220that are spaced from each other in the width direction, a connection wall230that connects the first side wall210and the second side wall220to each other in the width direction, and a support wall24that extends from a rear end of the second side wall220toward the first side wall210. The second spring support portion200includes a first support shaft251that extends from the first side wall210in the width direction, a second support shaft252that extends from the second side wall220in the width direction, and a holding portion253that extends from the first side wall210in the width direction.

The first side wall210and the second side wall220each have a plate shape whose plate thickness direction is the with the width direction. Meanwhile, the connection wall230and the support wall240each have a plate shape whose plate thickness direction is a direction perpendicular to the width direction. A thicknesses of each of the first support shaft251and the second support shaft252is set as a size depending on a size of the torsion spring50. The holding portion253is positioned in such a way as to be spaced from the first support shaft251. The holding portion253may have a cylindrical shape or a semi-cylindrical shape, or may have a polygonal column shape.

The torsion spring50includes a coil portion51, a first arm52that extends from a first end of the coil portion51, and a second arm53that extends from a second end of the coil portion51. The first arm52extends in a tangential direction of the coil portion51, and is then bent in an axial direction of the coil portion51. In the following description, the bent part of the first arm52is referred to as a distal end of the first arm52. In other words, the distal end of the first arm52does not mean a distal end surface of the first arm52, but means the part that is in the first arm52and to which a load for elastically deforming the torsion spring50can be applied. The second arm53extends in a tangential direction of the coil portion51. A diameter of the first arm52is smaller than each of a width of the communication groove161and a height of the slide space162in the first spring support portion100. A length of the second arm53is shorter than a length of the first arm52.

<Method for Manufacturing Roof Structure10>

The following describes a method for manufacturing the roof structure10. Concerning the method for manufacturing the roof structure10, it is assumed that the components of the roof structure10are already prepared.

The method for manufacturing the roof structure10includes a spring temporary assembly step, a deflector attachment step, and a spring attachment step. In the following description, a configuration on one side in the roof structure10in the width direction is described.

As illustrated inFIG.5andFIG.6, at the spring temporary assembly step, the torsion spring50is temporarily assembled to the second spring support portion200of the deflector40. Specifically, the coil portion51of the torsion spring50is disposed between the first side wall210and the second side wall220of the second spring support portion200. At this time, the first support shaft251and the second support shaft252are inserted into respective both end portions of the coil portion51of the torsion spring50. The first arm52of the torsion spring50contacts with the holding portion253, and the second arm53of the torsion spring50contacts with the support wall240. Thus, a state where the torsion spring50is temporarily assembled means a state where the coil portion51and the second arm53are supported by the second spring support portion200, and the first arm52is held by the holding portion253of the second spring support portion200.

The torsion spring50is elastically deformed in a state of being temporarily assembled to the second spring support portion200. Specifically, the first arm52and the second arm53are relatively closer to each other in a peripheral direction of the coil portion51, as compared to a state where no load is applied to the torsion spring50. In the following description, such elastic deformation of the torsion spring50is referred to as “compressive deformation”.

As illustrated inFIG.7, at the deflector attachment step, the deflector40is attached to the deflector support portion22of the frame11. Specifically, the proximal end of the deflector arm42is pressed against the support shaft23of the deflector support portion22in a state where the longitudinal direction of the deflector arm42is the up-down direction. Then, the support shaft23of the deflector support portion22is accommodated in the support hole43of the deflector arm42. Thus, the deflector40is rotatable around the axis of the support shaft23, i.e., around the axis extending in the width direction. When the deflector40is rotated around the axis of the support shaft23, the distal end of the first arm52of the torsion spring50draws a rotation trajectory of a circular arc shape. Herein, the rotation trajectory of the distal end of the first arm52of the torsion spring50intersects with the first upper surface131of the first spring support portion100.

As illustrated inFIG.8andFIG.9, at the spring attachment step, the first arm52of the torsion spring50shifts from a state of being held by the second spring support portion200to a state of being supported by the first spring support portion100. At the spring assembly step, first, the deflector40is rotated in a direction of being inclined more deeply to a front side. Then, the distal end of the first arm52of the torsion spring50supported by the second spring support portion200contacts with the first upper surface131of the first upper wall130of the first spring support portion100. At this time, the distal end of the first arm52is positioned on a lower side of a line segment that connects, to each other, the rotational axis of the deflector40and an axis passing through the center of the coil portion51. Thus, when the deflector40is further rotated in the direction of being inclined more deeply to a front side, the distal end of the first arm52moves rearward while sliding on the first upper surface131of the first upper wall130. When the distal end of the first arm52slides on the first upper surface131, an amount of compressive deformation of the torsion spring50increases. Accordingly, the first arm52is separated from the holding portion253of the second spring support portion200. In this regard, the holding portion253of the second spring support portion200can hold the first arm52until the first arm52contacts with the first spring support portion100.

When the deflector40is further rotated in the direction of being inclined more deeply to a front side, the distal end of the first arm52of the torsion spring50moves to a rear end of the first upper wall130. In other words, the distal end of the first arm52and the first upper surface131finish the sliding. Then, restoration force of the torsion spring50causes the distal end of the first arm52to be displaced downward while passing through the communication groove161. As a result, the distal end of the first arm52contacts with the slide surface151of the lower wall150, and thereby, the distal end of the first arm52is brought into a state of being slidable on the slide surface151of the lower wall150. In other words, the distal end of the first arm52is accommodated in the slide space162between the lower wall150and each of the first upper wall130and the second upper wall140. Thus, the distal end of the first arm52of the torsion spring50is supported by the first spring support portion100while the torsion spring50is kept compressed and deformed.

The restoration force of the torsion spring50causes the distal end of the first arm52to move not only downward but also forward. Thus, as illustrated inFIG.9, the distal end of the first arm52is brought into a state of contacting with not only the slide surface151of the lower wall150but also the front wall110.

A position of the deflector40illustrated inFIG.9indicates a position of the deflector40when the movable panel13is opened, i.e., the position of the deflector40when the deflector40is not pushed down by the movable panel13. In other words, the position of the deflector40illustrated inFIG.9is “deployed position”.

In the present embodiment, as illustrated inFIG.9, when the deflector40is set at the deployed position, the distal end of the first arm52of the torsion spring50contacts with the front wall110of the first spring support portion100. Meanwhile, the first arm52of the torsion spring50is separated from the holding portion253of the second spring support portion200.

As illustrated inFIG.9, when the distal end of the first arm52of the torsion spring50is supported by the first spring support portion100, the spring attachment step is completed. When the rotation of the deflector40is continued in a state where the spring attachment step is completed, the deflector40is set at a retracted position illustrated inFIG.10. The retracted position is a position closer to the frame11than the deployed position in the up-down direction. When the deflector40is set at the retracted position, the deflector body41is set in such a way as to be along the housing31, and the two deflector arms42are set in such a way as to be along the two guide rails21. The deflector body41is accommodated in the accommodation portion31aof the housing31.

<Effects of Present Embodiment>

The following describes a case where the movable panel13is opened from the fully closing position. When the movable panel13is positioned at the fully closing position, the movable panel13has pushed the deflector40down toward the frame11. Thus, as illustrated inFIG.10, the deflector40is set at the retracted position. When opening operation of the movable panel13is requested from a user of the vehicle, the movable panel13is opened toward the fully opening position. When the movable panel13is opened, the movable panel13is separated from the deflector40, and thereby, the force pushing the movable panel13down toward the frame11is removed. As a result, due to the restoration force of the torsion spring50, the deflector40is rotated from the retracted position illustrated inFIG.10to the deployed position illustrated inFIG.9. Thus, the deflector40can adjust an airflow near a front end of the opening portion15when the vehicle travels. In other words, the deflector40can suppress a low-frequency noise that makes the user uncomfortable.

The following describes a case where the movable panel13is closed from the fully opening position. When the movable panel13is positioned at the fully opening position, the deflector40is set at the deployed position illustrated inFIG.9, due to the restoration force of the torsion spring50. When closing operation of the movable panel13is requested from the user of the vehicle, the movable panel13is operated in a closing direction. When the movable panel13reaches the vicinity of the fully closing position, the movable panel13starts to push the deflector40down toward the frame11. As a result, the deflector40is rotated from the deployed position illustrated inFIG.9toward the retracted position illustrated inFIG.10while compressing and deforming the torsion spring50. When the movable panel13reaches the fully closing position, the deflector40is set at the retracted position.

Both in the case where the deflector40is positioned at the deployed position illustrated inFIG.9and in the case where the deflector40is positioned at the retracted position illustrated inFIG.10, the distal end of the first arm52of the torsion spring50is separated from the holding portion253of the second spring support portion200. Thus, the holding portion253of the second spring support portion200does not affect movement of the deflector40between the retracted position and the deployed position.

As illustrated inFIG.9andFIG.10, when the deflector40is rotated between the retracted position and the deployed position, in the front-rear direction, a position of the first spring support portion100does not change, and meanwhile, a position of the second spring support portion200changes. Thus, when the deflector40is rotated between the retracted position and the deployed position, the distal end of the first arm52of the torsion spring50moves along the slide surface151of the first spring support portion100in the front-rear direction. Thus, the first spring support portion100supports the distal end of the first arm52of the torsion spring50in such a way as to be movable in the front-rear direction.

<Effects of Present Embodiment>

(1) The torsion spring50can be temporarily assembled only to the second spring support portion200before the spring attachment step. Specifically, in addition to causing the coil portion51and the second arm53of the torsion spring50to be supported by the second spring support portion200, the first arm52is caused to be held by the holding portion253of the second spring support portion200in a state where the torsion spring50is compressed and deformed. Accordingly, at the spring attachment step, a working person or a working apparatus does not need to cause the distal end of the first arm52of the torsion spring50to be supported by the first spring support portion100while compressing and deforming the torsion spring50. In other words, at the spring attachment step, workability is improved at the time of causing the first arm52of the torsion spring50to be supported by the first spring support portion100. Therefore, the roof structure10can reduce a labor required for the manufacturing.

(2) At the spring attachment step, the deflector40is rotated toward the retracted position while the first arm52of the torsion spring50is kept held by the holding portion253, and thereby, the first arm52of the torsion spring50can be caused to be supported by the first spring support portion100. Specifically, when the distal end of the first arm52slides on the first upper surface131of the first spring support portion100, and thereby, the first arm52is separated from the holding portion253, and the distal end of the first arm52is guided into the slide space162of the first spring support portion100. Accordingly, a labor required for manufacturing the roof structure10is further reduced. The first spring support portion100can more firmly support the distal end of the first arm52of the torsion spring50.

(3) At the spring attachment step, the distal end of the first arm52of the torsion spring50moves rearward while sliding on the first upper surface131of the first spring support portion100. In this regard, the first spring support portion100includes, on a rear side of the first upper wall130, the second upper wall140extending to an upper side of the first upper wall130. Therefore, by the second upper wall140, the first spring support portion100can restrict rearward movement of the distal end of the first arm52of the torsion spring50. Thus, the first spring support portion100can guide the distal end of the first arm52of the torsion spring50toward the lower wall150via the communication groove161.

Further, the second upper wall140includes the second front surface142bthat is inclined in such a way as to extend downward while being shifted forward. Thus, the first spring support portion100can more easily guide the distal end of the first arm52of the torsion spring50toward the lower wall150.

(4) Under the condition that the deflector40is set at the deployed position, when external force of further rotating the deflector40in a deploying direction is applied, the first arm52of the torsion spring50contacts with the holding portion of the second spring support position200. In other words, when external force of further rotating the deflector40from the deployed position in the deploying direction is applied, the holding portion253of the second spring support portion200can suppress rotation of the deflector40in the deploying direction.

Modified Examples

The present embodiment can be modified and implemented as in the following. The present embodiment and the following modified examples can be implemented in combination with each other within a range where technical contradiction does not occur.A configuration of the first spring support portion100can be appropriately modified. The following describes roof structures10X,10Y, and10Z according to the modified examples with reference toFIG.11toFIG.13. In the modified examples, the same configurations as those in the above-described embodiment are denoted by the same reference signs, and the description thereof is omitted.As illustrated inFIG.11, in the roof structure10X, a first spring support portion100X includes a front wall110, the first upper wall130, a second upper wall140X, and the lower wall150. The second upper wall140X includes a second upper surface143that faces upward, and a second front surface144that faces forward. In the up-down direction, the second upper surface143is positioned at the same height as that of the first upper surface131. The second upper surface143includes a second upper surface143athat extends upward while being shifted rearward, and a second upper surface143bthat extends rearward from an rear end of the second upper surface143a. In other words, a front end portion of the second upper wall140X is beveled. The second upper surface143acorresponds to “second inclined surface”.

The following considers a case where the distal end included in the first arm52of the torsion spring50and moving rearward comes into contact with the second upper wall140X at the spring attachment step. Herein, the second upper surface143of the second upper wall140X includes the second upper surface143athat is inclined toward the lower wall150. Thus, in the above-described case, the first spring support portion100X can guide the distal end of the first arm52of the torsion spring50toward the lower wall150.As illustrated inFIG.12, in the roof structure10Y, a first spring support portion100Y includes the front wall110, a first upper wall130Y, the second upper wall140X, and the lower wall150. The first upper wall130Y includes a first upper surface133that faces upward, and a first rear surface132that faces rearward. The first upper surface133includes a first upper surface133athat extends rearward, and a first upper surface133bthat extends downward from a rear end of the first upper surface133awhile being shifted rearward. In other words, a rear end portion of the first upper wall130Y is beveled. The first upper surface133bcorresponds to “first inclined surface”.

At the spring attachment step, the distal end of the first arm52of the torsion spring50moves rearward while sliding on the first upper surface133of the first spring support portion100Y. Herein, the first upper surface133includes the first upper surface133bthat is inclined toward the lower wall150. Thus, the first spring support portion100Y can guide the distal end of the first arm52of the torsion spring50toward the lower wall150.As illustrated inFIG.13, in the roof structure10Z, a first spring support portion100Z of the housing31includes the front wall110, a first upper wall130Z, the second upper wall140X, and the lower wall150. The first upper wall130Z includes a first upper surface134that faces upward, and a first rear surface132that faces rearward. The first upper surface134extends downward while being shifted rearward. Under the condition that the holding portion253of the second spring support portion200holds the first arm52of the torsion spring50, the first upper surface134of the first upper wall130intersects with the trajectory of the distal end of the first arm52when the deflector40is rotated. The first upper surface134corresponds to “guide surface” and the “first inclined surface”.

When the deflector40is rotated toward the retracted position at the spring attachment step, the distal end of the first arm52of the torsion spring50contacts with the first upper surface134. Subsequently, when the deflector40is further rotated toward the retracted position, the distal end of the first arm52of the torsion spring50moves toward the communication groove161while sliding on the first upper surface134. Thus, the first spring support portion100Z can more reliably guide the distal end of the first arm52of the torsion spring50toward the lower wall150.The torsion spring50may be a double torsion spring.A shape of the first spring support portion100can be appropriately modified. For example, the first spring support portion100may have a configuration that can support the distal end of the first arm52of the torsion spring50at the spring attachment step while maintaining elastic deformation of the torsion spring50held by the holding portion253of the second spring support portion200.The first spring support portion100does not need to include the second upper wall140.In the above-described embodiment, the first arm52of the torsion spring50contacts with the front wall110of the first spring support portion100, and thereby, the deployed position of the deflector40is defined, but the deployed position of the deflector40may be defined by another method. For example, the first arm52of the torsion spring50may be caused to contact with the holding portion253of the second spring support portion200, and thereby, the deployed position of the deflector40may be defined. In other words, after the spring attachment step, the holding portion253of the second spring support portion200may contact with the first arm52of the torsion spring50.At the spring attachment step in the above-described embodiment, the distal end of the first arm52of the torsion spring50contacts with the first upper surface131of the first upper wall130of the first spring support portion100. In other words, the rotation trajectory of the distal end of the first arm52intersects with the first upper surface131. In the modified example, the rotation trajectory of the distal end of the first arm52may pass through the communication groove161between the first upper wall130and the second upper wall140, and may intersect with the slide surface151of the lower wall150. In this case, at the spring attachment step, the distal end of the first arm52contacts with the lower wall150without contacting with the first upper wall130and the second upper wall140. In other words, it can be said that the lower wall150includes a surface corresponding to “guide surface”, in addition to the slide surface151. In this case, the slide surface151and the guide surface may share a part thereof.The holding portion253of the second spring support portion200may hold the first arm52in such a way that the torsion spring50is not elastically deformed. In this case, preferably, a gap between the holding portion253and the first arm52is set small in such a way that the torsion spring50does not inadvertently move relative to the second spring support portion200.The numbers of the first spring support portions100and the second spring support portions200can be appropriately modified. For example, the front frame30may include one first spring support portion100at a central portion in the width direction. In this case, the deflector40may include one second spring support portion200in a central portion in the width direction.Structures of the first spring support portion100and the second spring support portion200can be appropriately modified. For example, as illustrated inFIG.7, in the torsion spring50of the above-described embodiment, the distal end of the first arm52is positioned closer to the rotation center of the deflector40than the coil portion51. In other words, the first arm52held by the holding portion253extends toward the proximal end portion of the deflector40relative to the coil portion51while being shifted in a retracting direction of the deflector40. In contrast to this, in the torsion spring50of the modified example, the coil portion51may be positioned closer to the rotation center of the deflector40than the distal end of the first arm52. In other words, the first arm52held by the holding portion253may extend toward the distal end portion of the deflector40relative to the coil portion51while being shifted in the retracting direction of the deflector40. The first spring support portion100does not need to include the front wall110, and in the first spring support portion100, the lower wall150may extend to a front side of the first upper wall130.

In such a case, when the deflector40is rotated at the spring attachment step, the distal end of the first arm52held by the holding portion253moves forward while sliding on the first upper surface131of the first upper wall130. Then, when the distal end of the first arm52of the torsion spring50moves to a front end of the first upper wall130, the restoration force of the torsion spring50causes the distal end of the first arm52to be displaced downward. As a result, the distal end of the first arm52contacts with the slide surface151of the lower wall150, and thereby, the distal end of the first arm52is brought into a state of being slidable on the slide surface151of the lower wall150. In other words, the distal end of the first arm52of the torsion spring50is supported by the first spring support portion100.The first spring support portion100may be provided in the side frame20that constitutes the frame11. In this case, the second spring support portion200may be provided in the deflector arm42.In the deflector40, the second spring support portion200does not need to include the holding portion253. In this case, preferably, the deflector40includes the holding portion253at a part different from the second spring support portion200. In this case, preferably, a shape of the torsion spring50is modified depending on a position of the holding portion253.

The following describes means in order to solve the above-described problem and its advantageous effect.

[Aspect 1] A vehicle roof structure that solves the above-described problem includes a frame and a deflector device. The frame defines an opening portion that is opened and closed by a movable panel. The deflector device includes a deflector and a torsion spring. The deflector is supported in such a way as to be rotatable around an axis extending in a width direction, and rotates between a retracted position and a deployed position that is more displaced upward relative to the opening portion than the retracted position. The torsion spring includes a coil portion, a first arm that extends from a first end of the coil portion, and a second arm that extends from a second end of the coil portion, and is elastically compressed and deformed as the deflector is displaced from the deployed position toward the retracted position. The frame includes a first spring support portion that supports the first arm of the torsion spring in such a way as to be movable in a front-rear direction. The deflector includes a second spring support portion that supports the coil portion and the second arm of the torsion spring, and a holding portion that can hold the first arm. The first spring support portion includes a guide surface on which the first arm is slidable. Under a condition that the holding portion holds the first arm, when the deflector rotates toward the retracted position, the first arm slides on the guide surface, and is thereby shifted to a state of being supported by the first spring support portion.

In the vehicle roof structure, when the movable panel closes the opening portion, the movable panel pushes down the deflector. Thus, the deflector is set at the retracted position while compressing and deforming the torsion spring. Meanwhile, when the movable panel opens the opening portion, the movable panel is separated from the deflector. Thus, the deflector is set at the deployed position by restoration force of the torsion spring.

In a case of manufacturing the vehicle roof structure, the first arm and the second arm of the torsion spring need to be supported by the first spring support portion of the frame and the second spring support portion of the deflector, respectively. According to the above-described configuration, the torsion spring can be temporarily assembled only to the second spring support portion before a spring attachment step of causing the first arm of the torsion spring to be supported by the first spring support portion. Specifically, the coil portion and the second arm of the torsion spring are caused to be supported by the second spring support portion, and in addition, the first arm can be caused to be held by the holding portion of the second spring support portion.

Thus, at the spring attachment step, when the deflector is rotated toward the retracted position while the first arm of the torsion spring is kept held by the holding portion of the second spring support portion, the first arm slides on the guide surface of the first spring support portion. Then, accompanying sliding between the first arm of the torsion spring and the guide surface of the first spring support portion, the first arm is brought into a state of being supported by the first spring support portion. Accordingly, merely rotating the deflector toward the retracted position at the spring attachment step causes the first arm of the torsion spring to be supported by the first spring support portion. Therefore, the vehicle roof structure can reduce a labor required for the manufacturing.

[Aspect 2] In the vehicle roof structure according to the aspect 1, the first spring support portion may include an upper wall and a lower wall. The upper wall includes the guide surface and extends in the front-rear direction. The lower wall is positioned on a lower side than the upper wall and extends longer in the front-rear direction than the upper wall. The first spring support portion may support the first arm between the upper wall and the lower wall. Under a condition that the holding portion holds the first arm, when the deflector rotates toward the retracted position, the guide surface may guide the first arm to a front side of a front end of the upper wall or to a rear side of a rear end of the upper wall.

At the spring attachment step, when the deflector is rotated toward the retracted position while the first arm of the torsion spring is kept held by the holding portion of the second spring support portion, the first arm slides on the guide surface of the first spring support portion. When, accompanying sliding between the first arm of the torsion spring and the guide surface of the first spring support portion, the first arm moves to a front side of the front end of the upper wall of the first spring support portion or to a rear side of the rear end of the upper wall, the first arm is displaced toward the lower wall of the first spring support portion. In other words, the first arm of the torsion spring is guided to an area between the upper wall and the lower wall of the first spring support portion. Thus, even in a case of adopting the configuration in which the first spring support portion supports the first arm of the torsion spring between the upper wall and the lower wall, merely rotating the deflector toward the retracted position at the spring attachment step can cause the first arm to be supported by the first spring support portion.

[Aspect 3] In the vehicle roof structure according to the aspect 2, when the upper wall is defined as a first upper wall, the first spring support portion may include a second upper wall that extends rearward in a state of being spaced from a rear end of the first upper wall. The second upper wall may extend to an upper side than the first upper wall. Under a condition that the holding portion holds the first arm, when the deflector rotates toward the retracted position, the guide surface may guide the first arm to a rear side of a rear end of the first upper wall.

At the spring attachment step, the first arm of the torsion spring moves rearward while sliding on the guide surface of the first spring support portion. In this regard, the first spring support portion of the above-described configuration includes the second upper wall positioned on a rear side of the first upper wall and extending to an upper side than the first upper wall. For this reason, the first spring support portion can restrict rearward movement of the first arm of the torsion spring by the second upper wall. Thus, the first spring support portion can guide the first arm of the torsion spring toward the lower wall via a gap between the first upper wall and the second upper wall.

[Aspect 4] In the vehicle roof structure according to the aspect 3, a second upper surface being included in the second upper wall and facing upward may include a second inclined surface that is inclined in such a way as to extend downward while being shifted forward.

The following considers a case where the first arm of the torsion spring moving rearward comes into contact with the second upper wall at the spring attachment step. Herein, the second upper surface of the second upper wall includes the second inclined surface that is inclined toward the lower wall. Thus, the first spring support portion can guide the first arm of the torsion spring toward the lower wall in the above-described case.

[Aspect 5] In the vehicle roof structure according to the aspect 3 or 4, the guide surface of the first upper wall may include a first inclined surface that is inclined in such a way as to extend downward while being shifted rearward.

At the spring attachment step, the first arm of the torsion spring moves rearward while sliding on the guide surface of the first spring support portion. Herein, the guide surface includes the first inclined surface that is inclined toward the lower wall. Thus, the first spring support portion can guide the first arm of the torsion spring toward the lower wall.

[Aspect 6] In the vehicle roof structure according to the aspect 5, under a condition that the holding portion holds the first arm, the first inclined surface of the upper wall may intersect with a rotation trajectory of the first arm when the deflector rotates toward the retracted position.

When the deflector is rotated toward the retracted position at the spring attachment step, the first arm of the torsion spring contacts with the first inclined surface, and then slides on the first inclined surface. Thus, the first spring support portion can more reliably guide the first arm of the torsion spring toward the lower wall.

[Aspect 7] In the vehicle roof structure according to any one of the aspects 1 to 6, the holding portion may hold the first arm in a state of making the torsion spring elastically compressed and deformed.

According to the above-described configuration, the torsion spring can be temporarily assembled only to the second spring support portion before the spring attachment step of causing the first arm of the torsion spring to be supported by the first spring support portion. Specifically, the coil portion and the second arm of the torsion spring are caused to be supported by the second spring support portion, and in addition, the first arm can be caused to be held by the holding portion of the second spring support portion in a state where the torsion spring is compressed and deformed. Accordingly, at the spring attachment step, a working person or a working apparatus does not need to cause the first arm to be supported by the first spring support portion while largely compressing and deforming the torsion spring. In other words, workability is further improved at a time of causing the first arm of the torsion spring to be supported by the first spring support portion.

[Aspect 8] A method for manufacturing the vehicle roof structure that can solve the above-described problem includes a spring temporary assembly step and a spring attachment step. The spring temporary assembly step includes causing the second spring support portion to support the coil portion and the second arm, and causing the holding portion to hold the first arm. The spring attachment step includes, after the spring temporary assembly step, rotating the deflector toward the retracted position, thereby causing the first arm to slide on the guide surface, and causing the first arm to be supported by the first spring support portion.

The method for manufacturing the vehicle roof structure can achieve an advantageous effect equivalent to that of the above-described vehicle roof structure.

[Aspect 9] In the method for manufacturing the vehicle roof structure according to the aspect 8, the first spring support portion may include an upper wall including the guide surface and extending in a front-rear direction, and a lower wall positioned on a lower side than the upper wall and extending longer in the front-rear direction than the upper wall. Under a condition that the holding portion holds the first arm, when the deflector rotates toward the retracted position, the guide surface may guide the first arm to a front side of a front end of the upper wall or to a rear side of a rear end of the upper wall. The spring attachment step may include causing the first arm to slide on the guide surface, and thereby setting the first arm between the upper wall and the lower wall of the first spring support portion.

The method for manufacturing the vehicle roof structure can achieve an advantageous effect equivalent to that of the above-described vehicle roof structure.