# Patent

## Title
Structure for upper part of vehicle body

## Abstract

A structure for an upper part of vehicle body includes: right and left side rail members extending in a vehicle front-rear direction; a roof member having right and left end portions in a vehicle width direction supported by the right and left side rail members, respectively; and gussets connected at one ends thereof to the respective side rail members, each extending from one end upwardly and inwardly in the vehicle width direction, and connected at the other end thereof to the roof member.

## Background
TECHNICAL FIELD
The present invention relates to a structure for upper part of vehicle body of a vehicle such as, for example, an automobile.
BACKGROUND ART
For example, Patent Literature 1 discloses a roof structure, as shown in FIG. 6, in which a joint bracket 4 is provided to a corner portion at an inner side 3 of a vehicle compartment where a center pillar 1 at a side part of the vehicle body is connected to a roof panel 2 at an upper part of the vehicle body.
This joint bracket 4 has: one end (upper end) joined by welding to a lower surface of a bead part 5 provided to the roof panel 2; and the other end (lower end) fastened, with a bolt 8a and a nut 8b, to a single inner panel 7 constituting a closed cross section of a roof side member 6. Note that the bead part 5 has such a sectional shape that the roof panel 2 is divided into two tensile surfaces 9a, 9b, forming a recessed groove open outwardly of the vehicle compartment.
CITATION LIST
Patent Literature
Patent Literature 1: JP 2001-233243 A
SUMMARY OF INVENTION
Technical Problem
However, in the roof structure disclosed in Patent Literature 1, the roof panel 2 is a member constituting a design surface of the vehicle, and providing the bead part 5 having the recessed groove, as seen from the outside of the vehicle compartment, decreases the design appearance. Moreover, since the one end (upper end) of the joint bracket 4 is directly welded to the lower surface of the bead part 5, a welding mark resulting from the welding is visible on the design surface of the roof from the outside of the vehicle compartment, and the roof panel 2 may be thermally strained by the heating action during the welding.
Further, suppose a case where the roof design is developed which, for example, excludes the bead part 5 but includes the roof panel 2 having a single tensile surface in consideration of the design. In this case, the single roof panel 2, to which the one end (upper end) of the joint bracket 4 is joined, does not have a sufficient strength. This brings about a problem that the stiffness and the strength of the upper part of the vehicle body deteriorate.
Furthermore, since the other end (lower end) of the joint bracket 4 is bolt-fastened to the single inner panel 7 with the bolt 8a and the nut 8b, the single inner panel 7 does not have a sufficient strength, either, as in the case of the one end. This brings about the problem that the stiffness and the strength of the upper part of the vehicle body deteriorate.
An object of the present invention is to provide a structure for upper part of vehicle body capable of ensuring the stiffness and the strength at a corner portion inside a vehicle compartment where a roof member is connected to a pillar, without deteriorating the design.
Solution to Problem
To achieve the above object, the present invention is a structure for upper part of vehicle body characterized as follows. The structure for upper part of vehicle body includes: a pair of right and left side rail members extending in a vehicle front-rear direction; a roof member having right and left end portions in a vehicle width direction supported by the pair of side rail members respectively; and gussets connected at one ends thereof to the respective side rail members, extended from the one ends upwardly and inwardly in the vehicle width direction, and connected at the other ends thereof to the roof member. The roof member includes: a roof panel constituting a design surface; a roof arch disposed below the roof panel and extending in the vehicle width direction between the pair of side rail members; and roof stiffeners disposed below the roof arch and disposed on inner sides of the respective side rail members in the vehicle width direction to extend in the vehicle front-rear direction along the respective side rail members, the roof stiffeners being connected to outer end portions of the roof arch in the vehicle width direction and constituting a first closed cross section. The other end of each gusset is connected to the roof stiffener, forming a second closed cross section adjacent to the first closed cross section.
According to the present invention, the roof arch and the roof stiffener form the first closed cross section, while the side rail member, the roof stiffener, and the gussets form the second closed cross section. These first closed cross section and second closed cross section are disposed adjacent to each other. In the load transmission in the vehicle width direction between the side rail member and the roof member, a load is transmitted through the two adjacent closed cross sections. As a result, the present invention enhances the load transmission efficiency in the vehicle width direction, making it possible to increase the stiffness and the strength of the upper part of the vehicle body.
Moreover, according to the present invention, it is no longer necessary to provide a bead part having a recessed groove as in the conventional technique, and the gusset is not directly connected to the roof panel constituting the design surface. Accordingly, it is possible to ensure the stiffness and the strength at a corner portion inside a vehicle compartment where the roof member is connected to a pillar, without deteriorating the design.
Further, the present invention is characterized as follows. Each roof stiffener has a hat-shaped cross-sectional portion formed of: a lower wall facing the roof panel in an up-down direction; an outer wall and an inner wall raised upwardly from the lower wall and facing each other in the vehicle width direction; an outer flange extending from an upper end of the outer wall outwardly in the vehicle width direction; and an inner flange extending from an upper end of the inner wall inwardly in the vehicle width direction. The outer flange of the roof stiffener is connected to an outer end portion of the roof panel in the vehicle width direction. The roof arch has: an arch main body connected to a lower surface of the roof panel; an arch curved portion formed by downwardly curving a portion of the arch main body, the portion being inward in the vehicle width direction of the outer end portion of the roof panel in the vehicle width direction; and an arch connection portion extending from a lower end of the arch curved portion outwardly in the vehicle width direction and connected to the outer flange of the roof stiffener. The roof panel, the arch curved portion and the arch connection portion of the roof arch, and the outer flange of the roof stiffener form a third closed cross section overlapping with the second closed cross section in the up-down direction of the vehicle.
According to the present invention, by forming the third closed cross section overlapping with the second closed cross section in the vehicle up-down direction, a load is transmitted in the vehicle width direction between the side rail member and the roof member through the first closed cross section, the second closed cross section, and the third closed cross section. As a result, the present invention further enhances the load transmission efficiency in the vehicle width direction, making it possible to further increase the stiffness and the strength of the upper part of the vehicle body.
Further, the present invention is characterized in that the third closed cross section is formed to overlap with the first closed cross section in the up-down direction of the vehicle with the roof arch therebetween.
According to the present invention, the first closed cross section and the second closed cross section are disposed adjacent to each other, and the third closed cross section is disposed to overlap with each of the first closed cross section and the second closed cross section in the vehicle up-down direction. With such positional relations that the first closed cross section, the second closed cross section, and the third closed cross section are adjacent to each other or overlap with each other in the up-down direction, efficient load transmissions are possible among the multiple closed cross sections, and the stiffness and the strength of the upper part of the vehicle body can be further increased.
Furthermore, the present invention is characterized in that each of the side rail members has: a rail inner connected to the one end of the gusset; and a rail outer connected to an outer side of the rail inner in the vehicle width direction, the rail inner and the rail outer forming a fourth closed cross section adjacent to the second closed cross section.
According to the present invention, by forming the fourth closed cross section adjacent to the second closed cross section, a load is transmitted in the vehicle width direction between the side rail member and the roof member through the first closed cross section, the second closed cross section, and the fourth closed cross section which are adjacent to each other. As a result, the present invention enhances the load transmission efficiency in the vehicle width direction, making it possible to further increase the stiffness and the strength of the upper part of the vehicle body.
Furthermore, the present invention is characterized by further including a pillar extending in the up-down direction of the vehicle and having an upper end connected to each of the side rail members, the pillar being disposed at a position overlapping with the gusset and the roof arch in the vehicle width direction in a top view of a vehicle body.
According to the present invention, the pillar, the gusset, and the roof arch are positioned to overlap with each other in the vehicle width direction when seen from the top, so that the pillar overlaps with the first to the fourth closed cross sections in the vehicle width direction. As a result, the present invention enhances the load transmission efficiency in the vehicle width direction from the pillar through the side rail member to the roof member, making it possible to further increase the stiffness and the strength of the side part and the upper part of the vehicle body.
In addition, according to the present invention, for example, a side impact load inputted to the pillar can be efficiently transmitted to the upper part of the vehicle body, thus enhancing the side impact performance. Further, a rollover load inputted to the roof member can be efficiently transmitted to the side part of the vehicle body, thus enhancing the rollover performance. Furthermore, when the vehicle turns a corner, a deformation load (deformation mode) or the like inputted to the pillar and the roof member can be spread to each of the upper part and the side part of the vehicle body, thus enhancing the deformation mode performance.
Note that, in the present invention, “connecting” and related similar terms used are meant to include, for example, “joining” by welding, adhesion, or the like, and “fastening” with bolt and nut, stud bolt, or the like.
Advantageous Effects of Invention
According to the present invention, it is made possible to obtain a structure for upper part of vehicle body capable of ensuring the stiffness and the strength at a corner portion inside a vehicle compartment where a roof is connected to a pillar, without deteriorating the design.



BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view from an inside of a left side part and an upper part of a vehicle having a structure for upper part of vehicle body according to an embodiment of the present invention;
FIG. 2 is a partially enlarged perspective view of a section A shown in FIG. 1;
FIG. 3 is a perspective view including a vertical cross section taken along the line in FIG. 2;
FIG. 4 is an end view taken along the line in FIG. 2;
FIG. 5 is a top view of a center pillar, a gusset, and a roof arch seen from the top; and
FIG. 6 is a partially exploded perspective cut view showing a roof structure according to a conventional technique.



DESCRIPTION OF EMBODIMENTS
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings as appropriate. Note that “front or rear” and “upper or lower,” indicated by the arrows in each drawing, indicate a front-rear direction and an up-down direction (vertical up-down direction) of the vehicle respectively, while “right or left” indicate a right-left direction (vehicle width direction) of the vehicle. Moreover, in the present embodiments, “connecting” between members is exemplified by, for example, “joining” by welding, adhesion, or the like, and “fastening” with bolt and nut, stud bolt, or the like, but is not limited thereto.
As shown in FIG. 1, a vehicle 10 having a structure for upper part of vehicle body according to an embodiment of the present invention includes: a pair of right and left side rail members 12 extending in the vehicle front-rear direction; a roof member 14 having right and left end portions in the vehicle width direction supported by the pair of side rail members 12 respectively; a pair of right and left side sills 16 extending in the vehicle front-rear direction below the pair of side rail members 12; and side panel parts 18 provided between corresponding pairs of the side rail members 12 and the side sills 16. Note that, in the present embodiment, a left side part of the vehicle 10 will be described in detail, and the description of a right side part disposed symmetrically to the left side part will be omitted.
As shown in FIG. 2, the vehicle 10 further includes a gusset 24 fastened at a lower end (one end) 24a thereof to one of the side rail members 12, extended from the lower end (one end) 24a upwardly and inwardly in the vehicle width direction, and fastened at an upper end (the other end) thereof to the roof member 14, with bolts 20 and nuts 22 (see FIG. 4). The gusset 24 is provided with: a pair of reinforcement ribs 25 formed to expand inwardly to a vehicle compartment and extending substantially in parallel to each other along the vehicle up-down direction; and bolt insertion holes 27 disposed in four corner portions.
Returning to FIG. 1, a front portion of the vehicle is provided with a front pillar 26 suspended between the left side rail member 12 and the left side sill 16. Moreover, provided between the front pillar 26 and the side panel part 18 is a center pillar (pillar) 28 extending in the vehicle up-down direction and having an upper end joined (connected) to the left side rail member 12 and a lower end joined to the side sill 16.
As shown in FIGS. 3 and 4, the center pillar 28 includes an outer pillar 28a located outside the vehicle compartment, and an inner pillar 28b located inside the vehicle compartment. An upper end of the outer pillar 28a is joined (welded) to a rail outer 36 to be described below, while the inner pillar 28b is fixed with the bolts 20 and the nuts 22 by fastening together with the gusset 24 and a rail inner 34. The center pillar 28 divides a left front door opening portion 30 and a left rear door opening portion 30b from each other (see FIG. 1).
As shown in FIGS. 3 and 4, the left side rail member 12 has: a side outer panel 32 located at the outermost side of the vehicle compartment and exposed to the outside of the vehicle compartment; the rail inner 34 to which the lower end (one end) 24a of the gusset 24 along the vehicle up-down direction is fastened (connected) with the bolts 20 and the nuts 22; and the rail outer 36 joined to an outer side of the rail inner 34 in the vehicle width direction.
As shown in FIGS. 3 and 4, the roof member 12 includes: a roof panel 38 constituting a design surface facing the outside of the vehicle compartment; a roof arch 40 disposed below the roof panel 38 in the vehicle up-down direction and extending in the vehicle width direction between the left side rail members 12; a roof stiffener 44 disposed below the roof arch 40 in the vehicle up-down direction and disposed on an inner side of the left side rail member 12 in the vehicle width direction to extend in the vehicle front-rear direction along the left side rail member 12, the roof stiffener 44 being joined (welded) to an outer end portion 42 of the roof arch 40 in the vehicle width direction; and multiple roof cross members 46a to 46c extending along the vehicle width direction and joined to the pair of side rail members 12 (see FIG. 1).
As shown in FIG. 1, a substantially rectangular-shaped sunroof opening portion 50 is formed in a vehicle-front portion of the roof member 12. The roof arch 40 is provided to surround the sunroof opening portion 50 when seen from the inside of the vehicle compartment.
As shown in FIGS. 3 and 4, the roof stiffener 44 has a hat-shaped cross-sectional portion 45 formed of: a lower wall 44a facing the roof panel 38 in the vehicle up-down direction; an outer wall 44b and an inner wall 44c raised upwardly from the lower wall 44a and facing each other in the vehicle width direction; an outer flange 44d extending from an upper end of the outer wall 44b outwardly in the vehicle width direction; and an inner flange 44e extending from an upper end of the inner wall 44c inwardly in the vehicle width direction. The outer flange 44d of the roof stiffener 44 is joined (welded) to an outer end portion 38a of the roof panel 38 in the vehicle width direction. Note that, in the vehicle up-down direction, the height dimension of the inner wall 44c is set higher than the height dimension of the outer wall 44b. 
At this joined portion, five panel end portions are stacked in the vehicle up-down direction and integrally joined (welded) to each other including, in the order of stacking from the uppermost layer toward the lowermost layer: the outer end portion 38a of the roof panel 38 in the vehicle width direction, the outer flange 44d of the roof stiffener 44, an inner end portion 32a of the side panel outer 32 in the vehicle width direction, an inner end portion 36a of the rail outer 36 in the vehicle width direction, and an inner end portion 34a of the rail inner 34 in the vehicle width direction.
A first closed cross section 48 is formed between the roof arch 40 and the roof stiffener 44, which are respectively located at an upper side and a lower side in the vehicle up-down direction. The first closed cross section 48 has a substantially triangular shape in the cross-sectional view, and is provided to extend along the vehicle front-rear direction.
The roof arch 40 has: an arch main body 40a having an upper flange 41 connected to a lower surface of the roof panel 38; an arch curved portion 40b formed by downwardly curving a portion of the arch main body 40a, the portion being inward in the vehicle width direction of the outer end portion 38a of the roof panel 38 in the vehicle width direction; and an arch connection portion 40c extending from a lower end of the arch curved portion 40b outwardly in the vehicle width direction and joined (welded) to the outer flange 44d of the roof stiffener 44. Note that the arch connection portion 40c is provided not to overlap, in the vehicle width direction, with the outer end portion 38a of the roof panel 38 in the vehicle width direction.
The upper end (the other end) 24b of the gusset 24 is fastened (connected) to the lower wall 44a of the roof stiffener 44 with the bolts 20 and the nuts 22, thereby forming a second closed cross section 52 adjacent to the first closed cross section 48 along the vehicle width direction. The second closed cross section 52 is formed substantially in a right triangle shape in the cross-sectional view.
The roof panel 38, the arch curved portion 40b and the arch connection portion 40c of the roof arch 40, and the outer flange 44d of the roof stiffener 44 form a third closed cross section 54 overlapping with the second closed cross section 52 in the vehicle up-down direction. The third closed cross section 54 is formed to overlap with the first closed cross section 48 in the vehicle up-down direction with the roof arch 40 therebetween. Moreover, the rail inner 34 and the rail outer 36 form a fourth closed cross section 56 adjacent to the second closed cross section 52 along the vehicle width direction.
Further, as shown in FIG. 5, when the vehicle (vehicle body) is seen from the top, the pillar inner 28b of the center pillar 28, the gusset 24, and the roof arch 40 are disposed at positions overlapping with each other in the vehicle width direction. Note that FIG. 5 is a top view of the pillar inner 28b, the gusset 24, and the roof arch 40 seen from the top without the side outer panel 32, the rail outer 36, and the rail inner 34 constituting the rail member 12, the pillar outer 28a, and the roof panel 38 on the vehicle 10.
The vehicle 10 having the structure for upper part of vehicle body according to the present embodiment is basically constructed as described above. Next, the actions and the effects thereof will be described.
In the present embodiment, the roof arch 40 and the roof stiffener 44 joined to each other form the first closed cross section 48, while the rail inner 34 of the side rail member 12, the outer wall 44b and the outer flange 44d of the roof stiffener 44, and the gusset 24 form the second closed cross section 52.
In the present embodiment, the first closed cross section 48 and the second closed cross section 52 has a relation that these closed cross sections are disposed adjacent to each other along the vehicle width direction. In the load transmission in the vehicle width direction between the side rail member 12 and the roof member 14, a load is transmitted through the two adjacent closed cross sections. As a result, the present embodiment enhances the load transmission efficiency in the vehicle width direction, making it possible to increase the stiffness and the strength of the upper part of the vehicle body.
Specifically, this is because both of the two closed cross sections including the first closed cross section 48 and the second closed cross section 52 transmit a load to each other, making it possible to increase the number of load transmission paths as well as the load transmission area. Note that although a closed cross section basically has high stiffness and strength, providing two closed cross sections adjacent to each other can further increase the stiffness and the strength.
Moreover, in the present embodiment, it is no longer necessary to provide a bead part having a recessed groove as in the conventional technique, and the gusset 24 is not directly connected to the roof panel 38 constituting the design surface. Accordingly, it is possible to ensure the stiffness and the strength at a corner portion inside the vehicle compartment where the roof member 14 is connected to the center pillar 28, without deteriorating the design.
Further, in the present embodiment, by forming the third closed cross section 54 overlapping with the second closed cross section 52 in the vehicle up-down direction, a load is transmitted in the vehicle width direction between the side rail member 12 and the roof member 14 through the first closed cross section 48, the second closed cross section 52, and the third closed cross section 54. As a result, the present embodiment further enhances the load transmission efficiency in the vehicle width direction, making it possible to further increase the stiffness and the strength of the upper part of the vehicle body.
Furthermore, in the present embodiment, the first closed cross section 48 and the second closed cross section 52 has the relation that the closed cross sections are disposed adjacent to each other in the vehicle width direction, and the third closed cross section 54 has a relation thereto that the third closed cross section 54 is disposed to overlap with the first closed cross section 48 and the second closed cross section 52 in the vehicle up-down direction. With such positional relations that the first closed cross section 48, the second closed cross section 52, and the third closed cross section 54 are adjacent to each other or overlap with each other in the up-down direction, efficient load transmissions are possible among the multiple closed cross sections, and the stiffness and the strength of the upper part of the vehicle body can be further increased.
Furthermore, in the present embodiment, by forming the fourth closed cross section 56 adjacent to the second closed cross section 52 in the vehicle width direction, a load is transmitted in the vehicle width direction between the side rail member 12 and the roof member 14 through the first closed cross section 48, the second closed cross section 52, and the fourth closed cross section 56 which are adjacent to each other in the vehicle width direction. As a result, the present embodiment enhances the load transmission efficiency in the vehicle width direction, making it possible to further increase the stiffness and the strength of the upper part of the vehicle body.
Furthermore, in the present embodiment, there is a positional relation as shown in FIG. 5 that the center pillar 28, the gusset 24, and the roof arch 40 overlap with each other in the vehicle width direction when seen from the top, so that the center pillar 28 overlaps with the first to the fourth closed cross sections 48, 52, 54, and 56 in the vehicle width direction. As a result, the present embodiment enhances the load transmission efficiency in the vehicle width direction from the center pillar 28 through the side rail member 12 to the roof member 14, making it possible to further increase the stiffness and the strength of the side part and the upper part of the vehicle body.
Furthermore, in the present embodiment, for example, a side impact load inputted to the center pillar 28 can be efficiently transmitted to the upper part of the vehicle body, thus enhancing the side impact performance. Furthermore, for example, a rollover load inputted to the roof member 14 can be efficiently transmitted to the side part of the vehicle body, thus enhancing the rollover performance. Furthermore, for example, when the vehicle turns a corner, a deformation load (deformation mode) or the like inputted to the center pillar 28 and the roof member 14 can be spread to each of the upper part and the side part of the vehicle body, thus enhancing the deformation mode performance.
As has been described above, in the present embodiment, it is possible to obtain a structure for upper part of vehicle body capable of ensuring the stiffness and the strength at the corner portion inside the vehicle compartment where the roof member 14 is connected to the center pillar 28 with a simple structure using the gusset 24, without deteriorating the design.
REFERENCE SIGNS LIST


    10: Vehicle
    12: Side Rail Member
    14: Roof Member
    28: Center Pillar (Pillar)
    34: Rail Inner
    36: Rail Outer
    38: Roof Panel
    38a: Outer End Portion (of Roof Panel) in Vehicle Width Direction
    40: Roof Arch
    40a: Arch Main Body
    40b: Arch Curved Portion
    40c: Arch Connection Portion
    42: Outer End Portion (of Roof Arch) in Vehicle Width Direction
    44: Roof Stiffener
    44a: Lower Wall
    44b: Outer Wall
    44c: Inner Wall
    44d: Outer Flange
    44e: Inner Flange
    45: Hat-Shaped Cross-Sectional Portion
    48: First Closed Cross Section
    52: Second Closed Cross Section
    54: Third Closed Cross Section
    56: fourth Closed Cross Section

## Claims

1. A structure for upper part of vehicle body comprising:
a pair of right and left side rail members extending in a vehicle front-rear direction;
a roof member having right and left end portions in a vehicle width direction supported by the pair of side rail members respectively; and
gussets connected at one ends thereof to the respective side rail members, extended from the one ends upwardly and inwardly in the vehicle width direction, and connected at the other ends thereof to the roof member,
wherein
the roof member includes
a roof panel constituting a design surface,
a roof arch disposed below the roof panel and extending in the vehicle width direction between the pair of side rail members, and
roof stiffeners disposed below the roof arch and disposed on inner sides of the respective side rail members in the vehicle width direction to extend in the vehicle front-rear direction along the respective side rail members, the roof stiffeners being connected to outer end portions of the roof arch in the vehicle width direction and constituting a first closed cross section,

the other end of each gusset is connected to the roof stiffener, forming a second closed cross section adjacent to the first closed cross section,
each roof stiffener has a hat-shaped cross-sectional portion formed of:
a lower wall facing the roof panel in an up-down direction;
an outer wall and an inner wall raised upwardly from the lower wall and facing each other in the vehicle width direction;
an outer flange extending from an upper end of the outer wall outwardly in the vehicle width direction; and
an inner flange extending from an upper end of the inner wall inwardly in the vehicle width direction,

the outer flange of the roof stiffener is connected to an outer end portion of the roof panel in the vehicle width direction,
the roof arch has:
an arch main body connected to a lower surface of the roof panel;
an arch curved portion formed by downwardly curving a portion of the arch main body, the portion being inward in the vehicle width direction of the outer end portion of the roof panel in the vehicle width direction; and
an arch connection portion extending from a lower end of the arch curved portion outwardly in the vehicle width direction and connected to the outer flange of the roof stiffener, and
the roof panel, the arch curved portion and the arch connection portion of the roof arch, and the outer flange of the roof stiffener form a third closed cross section overlapping with the second closed cross section in the up-down direction of the vehicle.

2. The structure for upper part of vehicle body according to claim 1, wherein the third closed cross section is formed to overlap with the first closed cross section in the up-down direction of the vehicle with the roof arch therebetween.

3. The structure for upper part of vehicle body according to claim 1, wherein
each of the side rail members has:
a rail inner connected to the one end of the gusset; and
a rail outer connected to an outer side of the rail inner in the vehicle width direction, and

the rail inner and the rail outer form a fourth closed cross section adjacent to the second closed cross section.

4. The structure for upper part of vehicle body according to claim 1, further comprising
a pillar extending in the up-down direction of the vehicle and having an upper end connected to each of the side rail members, wherein
the pillar is disposed at a position overlapping with the gusset and the roof arch in the vehicle width direction in a top view of a vehicle body.