Patent Publication Number: US-11639200-B2

Title: Resin roof

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2020-217814 filed on Dec. 25, 2020, the disclosure of which is incorporated by reference herein. 
     BACKGROUND 
     Technical Field 
     The present disclosure relates to a resin roof. 
     Related Art 
     A ceiling interior trim for a vehicle has been known since heretofore (for example, see Japanese Patent Application Laid-Open (JP-A) No. 2011-225150) in which a molded foam body is formed integrally at a vehicle cabin outer side of a panel-shaped base member that is disposed to so as to face the vehicle cabin interior, at the vehicle cabin inner side of a roof panel of the vehicle. The shape of the vehicle cabin outer side of the molded foam body is substantially the same as the shape of the vehicle cabin inner side of the roof panel. The molded foam body is attached to the roof panel in a state in which the vehicle cabin outer side of the molded foam body is pressed against the vehicle cabin inner side of the roof panel. 
     When an inner layer fabricated of resin such as a molded foam body or the like is provided between a roof panel of a vehicle and a base member provided at the vehicle cabin inner side of the roof panel, as described above, and this inner layer is provided at an outer layer fabricated of resin that constitutes the roof panel, a main roof including the outer layer and the inner layer may be assembled to a sub-roof at the vehicle body side. Together with the outer layer, the sub-roof constitutes the roof panel. There is scope for improvement in structures that improve assembly characteristics when this main roof is being assembled to the sub-roof. 
     SUMMARY 
     Accordingly, an object of the present disclosure is to provide a resin roof that may improve assembly characteristics when a main roof is being assembled to a sub-roof. 
     In order to achieve the object described above, a resin roof according to a first aspect of the present disclosure includes: an outer layer fabricated of resin, the outer layer structuring a roof panel of a vehicle, and an inner layer fabricated of foam resin, the inner layer being provided in a predetermined region that excludes a peripheral edge portion of the outer layer; and a sub-roof fabricated of resin at a vehicle body side, the sub-roof being provided between a left and right pair of roof side rails of the vehicle in plan view, a joining portion at the peripheral edge portion of the outer layer being joined to the sub-roof and, together with the outer layer, the sub-roof structuring the roof panel. 
     According to the first aspect of the present disclosure, the joining portion of the peripheral edge portion of the outer layer of the main roof is joined to the sub-roof. Thus, when the main roof is assembled and joined to the sub-roof, the main roof is supported by the sub-roof. Therefore, assembly characteristics when the main roof is being assembled to the sub-roof are improved. 
     In a resin roof according to a second aspect of the present disclosure, in the resin roof according to the first aspect, the sub-roof is fabricated of a harder resin than the outer layer. 
     According to the second aspect of the present disclosure, because the sub-roof is fabricated of a harder resin than the outer layer, when the main roof is assembled and joined to the sub-roof, the main roof is stably supported by the sub-roof. 
     In a resin roof according to a third aspect of the present disclosure, in the resin roof according to the first aspect or the second aspect, the sub-roof is provided at a vehicle front side and a vehicle rear side of the main roof so as to support, respectively, a front windshield glass and a rear windshield glass. 
     According to the third aspect of the present disclosure, the sub-roof is provided at the vehicle front side and at the vehicle rear side of the main roof and the sub-roof supports each of the front windshield glass and the rear windshield glass. Therefore, the vehicle may be reduced in weight while support stiffness for the front windshield glass and the rear windshield glass is assured. When the sub-roof is fabricated of a harder resin than the outer layer, this support stiffness is even further assured. 
     In a resin roof according to a fourth aspect of the present disclosure, in the resin roof according to any one of the first to third aspects, the joining portion of the outer layer is joined to a joint portion of the sub-roof, the joint portion is joined by a rivet to a vehicle body side base member, and the joining of the joining portion of the outer layer to the joint portion includes joining of the joining portion to the rivet. 
     According to the fourth aspect of the present disclosure, the joined portion of the sub-roof is joined by rivets to the vehicle body side base member. The joining portion of the outer layer is joined to the joined portion of the sub-roof, including the rivets. As a result, ingression of water into a vehicle cabin through penetrating holes in which the rivets are inserted is prevented. 
     In a resin roof according to a fifth aspect of the present disclosure, in the resin roof according to the fourth aspect, a joining portion of the inner layer is joined to the vehicle body side base member. 
     According to the fifth aspect of the present disclosure, the joining portion of the inner layer is joined to the vehicle body side base member, to which the joined portion of the sub-roof is joined. Therefore, the main roof is more stable than in a structure in which a joining portion of an inner layer is not joined to a vehicle body side base member. 
     In a resin roof according to a sixth aspect of the present disclosure, in the resin roof according to any one of the first to fifth aspects, an outer edge of the peripheral edge portion of the outer layer and the sub-roof are sealed together. 
     According to the sixth aspect of the present disclosure, a gap between the outer edge of the peripheral edge portion of the outer layer and the sub-roof is sealed up. As a result, ingression of water into the vehicle cabin between the outer edge and the sub-roof is prevented. 
     According to the present disclosure as described above, assembly characteristics when the main roof is assembled to the sub-roof may be improved. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the present disclosure will be described in detail based on the following figures, wherein: 
         FIG.  1    is a perspective view showing a resin roof according to a present exemplary embodiment; 
         FIG.  2    is a sectional diagram cut along line X-X in  FIG.  1   ; and 
         FIG.  3    is a sectional diagram cut along line Y-Y in  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     Herebelow, an exemplary embodiment relating to the present disclosure is described in detail in accordance with the drawings. For convenience of description, the arrow UP that is shown where appropriate in the drawings indicates a vehicle upper direction, the arrow FR indicates a vehicle front direction, and the arrow LH indicates a vehicle left direction. Thus, in the following descriptions, where the directions upper and lower, front and rear, and left and right are recited without being particularly specified, the same represent upper and lower in the vehicle vertical direction, front and rear in the vehicle front-and-rear direction, and left and right in the vehicle left-and-right direction (the vehicle width direction). 
     As shown in  FIG.  1    and  FIG.  2   , a left and right pair of roof side rails  20  fabricated of metal that extend in the front-and-rear direction are provided at two vehicle width direction end portions of a roof  12  of a vehicle according to the present exemplary embodiment. Each roof side rail  20  is formed in a chamber shape by an under reinforcement  22  and an upper reinforcement  26  being joined to one another. In a sectional view seen in the vehicle front-and-rear direction, the under reinforcement  22  is formed substantially in a hat shape. In the sectional view seen in the vehicle front-and-rear direction, the upper reinforcement  26  is formed substantially in a flat plate shape. 
     That is, the roof side rail  20  is formed in the chamber shape by flange portions  24  of the under reinforcement  22  and flange portions  28  of the upper reinforcement  26  being joined to one another by spot welding or the like. The flange portions  24  are formed at a vehicle width direction inner side end portion and a vehicle width direction outer side end portion of the under reinforcement  22 . The flange portions  28  are formed at a vehicle width direction inner side end portion and a vehicle width direction outer side end portion of the upper reinforcement  26 . Penetrating holes  26 A with circular shapes are formed at plural predetermined positions of the upper reinforcement  26  that extends in the front-and-rear direction. 
     A vehicle width direction inner side end portion of a side member outer panel (below referred to as “the side member outer”)  14  is joined to the upper face of the upper reinforcement  26 . To describe this more specifically, a step portion  16  is integrally formed at the vehicle width direction inner side of the side member outer  14 . In the sectional view seen in the vehicle front-and-rear direction, the step portion  16  is inflected in a substantial “L” shape toward the lower side. A support portion  18  is integrally formed at a vehicle width direction inner side end portion of the step portion  16 . In the sectional view seen in the vehicle front-and-rear direction, the support portion  18  is inflected in a substantial “L” shape toward the lower side. 
     Penetrating holes  18 A with circular shapes are formed at plural predetermined positions of the support portion  18  that extends in the front-and-rear direction. The penetrating holes  18 A are in communication with the penetrating holes  26 A of the upper reinforcement  26 . Thus, the support portion  18  that is the vehicle width direction inner side end portion of the side member outer  14  is attached to the upper reinforcement  26  (the roof side rail  20 ) by shaft portions  64  of plural rivets  60  being inserted into the penetrating holes  18 A and the penetrating holes  26 A from the vehicle upper side and being crimped (being deformed from the shape depicted with virtual lines to the shape depicted with solid lines). 
     As shown in  FIG.  1   , three roof reinforcements  30  that are spaced apart in the front-and-rear direction are provided extending in the vehicle width direction between the left and right pair of roof side rails  20 . The roof reinforcements  30  are fabricated of metal and serve as vehicle body side base members. Below, the roof reinforcement  30  at the front side is referred to as the roof reinforcement  30 F, the roof reinforcement  30  at the middle side is referred to as the roof reinforcement  30 C, and the roof reinforcement  30  at the rear side is referred to as the roof reinforcement  30 B. 
     A front and rear pair of sub-roofs  40  fabricated of resin structure a roof panel of the roof  12 . In a plan view, the sub-roofs  40  are provided, respectively, in a region bounded by the roof reinforcement  30 F at the front side and the left and right pair of roof side rails  20  and in a region bounded by the roof reinforcement  30 B at the rear side and the left and right pair of roof side rails  20 . The sub-roofs  40 , which are provided in advance between the left and right pair of roof side rails  20 , also serve as vehicle body side base members. 
     Two main roofs  50  are arrayed at front and rear. In plan view, the main roofs  50  are provided, respectively, in a region bounded by the roof reinforcement  30 F at the front side (the sub-roof  40  at the front side), the roof reinforcement  30 C at the middle side, and the left and right pair of roof side rails  20  and in a region bounded by the roof reinforcement  30 B at the rear side (the sub-roof  40  at the rear side), the roof reinforcement  30 C at the middle side, and the left and right pair of roof side rails  20 . The main roofs  50  are described below. 
     The front and rear pair of sub-roofs  40  are formed in substantially rectangular flat plate shapes of a resin material with high strength and stiffness, such as glass fiber-reinforced plastic (GFRP) or the like. Plate thicknesses of the sub-roofs  40  are set to 2.0 mm or more. The front and rear pair of sub-roofs  40  support, respectively, an upper end portion of a front windshield glass (not shown in the drawings) and an upper end portion of a rear windshield glass (not shown in the drawings). 
     That is, the front and rear pair of sub-roofs  40  are formed of a resin material such as GFRP or the like with strength and stiffness high enough to enable support of, respectively, the upper end portion of the front windshield glass and the upper end portion of the rear windshield glass. The front and rear pair of sub-roofs  40  have similar structures. Accordingly, only the sub-roof  40  at the front side is described below. 
     As shown in  FIG.  3   , a step portion  42  is integrally formed at a rear portion of the sub-roof  40  at the front side. In a sectional view seen in the vehicle width direction, the step portion  42  is inflected toward the lower side in a substantial “L” shape. A support portion  44  is integrally formed at a rear end portion of the step portion  42 . In the sectional view seen in the vehicle width direction, the support portion  44  is inflected toward the lower side in a substantial “L” shape. 
     The support portion  44  of the sub-roof  40  extends in the vehicle width direction. The support portion  44  serves as a single joined portion to which a first joining portion  54 , which is described below, is joined. An upper face  44 U of the support portion  44  serves as a single joined portion that a first adhesive G 1 , which is described below, contacts. 
     The roof reinforcement  30 F at the front side is formed in a chamber shape by an under reinforcement  32 F and an upper reinforcement  36 F being joined to one another. The under reinforcement  32 F is formed substantially in a hat shape in the sectional view seen in the vehicle width direction. The upper reinforcement  36 F is formed substantially in a flat plate shape in the sectional view seen in the vehicle width direction. 
     That is, the roof reinforcement  30 F at the front side is formed into the chamber shape by flange portions  34 F formed at a front end portion and rear end portion of the under reinforcement  32 F and flange portions  38 F formed at a front end portion and rear end portion of the upper reinforcement  36 F being joined to one another by spot welding or the like. 
     A plural number of brackets  46  are integrally attached to the upper face at the front side of the upper reinforcement  36 F. In a sectional view seen in the vehicle front-and-rear direction, the brackets  46  are formed substantially in hat shapes protruding to the upper side. The brackets  46  are spaced apart in the vehicle width direction. More specifically, flange portions  48  that extend in the vehicle width direction at lower end portions of each bracket  46  are integrally joined to the upper face of the upper reinforcement  36 F by spot welding or the like. 
     In some embodiments, at least three of the brackets  46  are provided, at a vehicle width direction central portion and both of vehicle width direction end portions of the upper reinforcement  36 F. A circular penetrating hole  47 A is formed in an upper wall  47  of each bracket  46 . Circular penetrating holes  44 A are formed at the plural number (at least three) of predetermined positions of the support portion  44  of the sub-roof  40  that extends in the vehicle width direction. The penetrating holes  44 A are in communication with the penetrating holes  47 A. 
     Accordingly, the support portion  44  of the sub-roof  40  is attached to the upper reinforcement  36 F via the brackets  46 , by the shaft portions  64  of a plural number (at least three) of the rivets  60  being inserted into the penetrating holes  44 A and penetrating holes  47 A from the vehicle upper side and being crimped (being deformed from the shape depicted with virtual lines to the shape depicted with solid lines). Thus, the rear end portion of the sub-roof  40  is supported by the roof reinforcement  30 F at the front side via the bracket  46 . 
     A front-and-rear direction substantially central portion of the upper reinforcement  36 F of the roof reinforcement  30 F at the front side serves as a single joined portion to which a second joining portion  58 , which is described below, is joined. An upper face of the front-and-rear direction substantially central portion of the upper reinforcement  36 F serves as a single joined portion that a second adhesive G 2 , which is described below, contacts. 
     As shown in  FIG.  2    and  FIG.  3   , each main roof  50  according to the present exemplary embodiment includes an outer layer  52  in a substantially rectangular flat plate shape and an inner layer  56 . The inner layer  56  is integrally joined to the lower face of a predetermined region of the outer layer  52  that excludes a peripheral edge portion  52 A of the outer layer  52 . Together with the sub-roofs  40 , the outer layers  52  structure the roof panel of the roof  12 . The main roofs  50  at front and rear have similar structures. Accordingly, only the main roof  50  at the front side is described below. 
     The outer layer  52  is formed of a resin material featuring weather resistance such as, for example, acrylonitrile ethylene-propylene-diene styrene (AES) or the like. A plate thickness of the outer layer  52  is set from 1.0 mm to 2.5 mm. The inner layer  56  is structured by a molded body that is molded of a foam resin material (for example, expanded urethane foam or the like). The inner layer  56  is formed to be thicker than the outer layer  52 . More specifically, the plate thickness of the inner layer  56  differs according to position in the front-and-rear direction and is set to at least 10 mm. 
     Thus, because each main roof  50  includes the outer layer  52  fabricated of resin and the inner layer  56  fabricated of resin, and each sub-roof  40  is also fabricated of resin, a resin roof  10  is formed of the main roofs  50  and the sub-roofs  40 . The outer layers  52  are molded of a resin material (AES) that is harder and denser than the inner layers  56 , and the sub-roofs  40  are molded of a resin material (GFRP) that is harder than the outer layers  52 . 
     The first adhesive G 1  is provided in an annular shape at the lower face of the peripheral edge portion  52 A of each outer layer  52 . A region in which the first adhesive G 1  is provided serves as the first joining portion  54 , which serves as a joining portion of the outer layer  52 . As shown in  FIG.  3   , the first joining portion  54  at the front side is joined via the first adhesive G 1  to head portions  62  of the rivets  60  of the sub-roof  40  and to the support portion  44  (the upper face  44 U) including peripheries of the head portions  62 . 
     As shown in  FIG.  2   , the first joining portion  54  at the right side is joined via the first adhesive G 1  to the head portions  62  of the rivets  60  of the side member outer  14  and to the support portion  18  (an upper face  18 U) including peripheries of the head portions  62 . The same applies to the first joining portion  54  at the left side. Although not shown in the drawings, the first joining portion  54  at the rear side is joined via the first adhesive G 1  to an upper reinforcement of the roof reinforcement  30 C at the middle side. 
     As shown in  FIG.  2    and  FIG.  3   , the second adhesive G 2  is provided in an annular shape at outer periphery portions of the lower face of the inner layer  56 . A region in which the second adhesive G 2  is provided serves as the second joining portion  58 , which serves as a joining portion of the inner layer  56 . As shown in  FIG.  3   , the second joining portion  58  at the front side is joined via the second adhesive G 2  to a front-and-rear direction substantially central portion of the upper reinforcement  36 F of the roof reinforcement  30 F. 
     As shown in  FIG.  2   , the second joining portion  58  at the right side is joined via the second adhesive G 2  to the flange portion  28  at the vehicle width direction inner side of the roof side rail  20 . The same applies to the second joining portion  58  at the left side. Although not shown in the drawings, the second joining portion  58  at the rear side is joined via the second adhesive G 2  to a flange portion formed at a front end portion of the upper reinforcement of the roof reinforcement  30 C at the middle side. 
     As shown in  FIG.  2    and  FIG.  3   , an outer edge  52 B of the peripheral edge portion  52 A of the outer layer  52  is covered by a soft sealer S featuring weather resistance. That is, the outer edge  52 B at the front side is sealed up by the sealer S along with a portion of an upper face of the step portion  42  of the sub-roof  40 , and the outer edge  52 B at the right side is sealed up by the sealer S along with a portion of an upper face of the step portion  16  of the side member outer  14 . The same applies to the outer edge  52 B at the left side. Although not shown in the drawings, the outer edge  52 B at the rear side is sealed up by the sealer S along with a portion of the upper face of the upper reinforcement of the roof reinforcement  30 C at the middle side. 
     Now, operation of the resin roof  10  according to the present exemplary embodiment that is structured as described above (the main roofs  50  and the sub-roofs  40 ) is described. 
     The sub-roofs  40  are provided at the vehicle in advance. The sub-roofs  40  are provided at the vehicle front side and the vehicle rear side of the main roofs  50  and support, respectively, the front windshield glass and the rear windshield glass. The sub-roofs  40  are formed of a resin material that is harder than the outer layers  52  of the main roofs  50 . Therefore, even while the vehicle may be reduced in weight, support stiffnesses for the front windshield glass and the rear windshield glass may be assured. 
     The main roofs  50  are disposed at the roof  12  of the vehicle at which the sub-roofs  40  have been provided beforehand. That is, the first joining portion  54  (the first adhesive G 1 ) of the peripheral edge portion  52 A of the outer layer  52  of each main roof  50  and the second joining portion  58  (the second adhesive G 2 ) of the inner layer  56  are joined to the corresponding joined portions (joined surfaces). 
     More specifically, the first joining portion  54  is joined via the first adhesive G 1  to the upper face  44 U of the support portion  44  (including the head portions  62  of the rivets  60  and the peripheries of the head portions  62 ), the upper faces  18 U of the left and right support portions  18  (including the head portions  62  of the rivets  60  and the peripheries of the head portions  62 ), and the upper face of the upper reinforcement of the roof reinforcement  30 C at the middle side. 
     Meanwhile, the second joining portion  58  is joined via the second adhesive G 2  to the upper face of the upper reinforcement  36 F of the roof reinforcement  30 F at the front side, the upper faces of the flange portions  28  of the left and right roof side rails  20 , and the upper face of the flange portion of the roof reinforcement  30 C at the middle side. 
     The sub-roof  40  (including the support portion  44 ) is formed of a harder resin material than the outer layer  52  of the main roof  50 . That is, the first joining portion  54  (the peripheral edge portion  52 A) of the outer layer  52  is joined to the support portion  44  of the sub-roof  40  that is higher in hardness than the outer layer  52  of the main roof  50 . 
     Therefore, when the first joining portions  54  (the peripheral edge portions  52 A) of the main roofs  50  are joined to the support portions  44  of the sub-roofs  40 , the first joining portions  54  (the peripheral edge portions  52 A) of the main roofs  50  are stably supported by the support portions  44  of the sub-roofs  40 . Thus, assembly characteristics when the main roofs  50  are being attached to the sub-roofs  40  may be improved. 
     Because the inner layer  56  is provided in advance at each main roof  50  to be assembled to the sub-roof  40 , the inner layer  56  may be easier to provide than if the inner layer  56  was provided to a structure in which the main roof  50  and the sub-roof  40  are formed integrally (i.e., operational characteristics for providing the inner layer  56  may be improved). 
     The support portion  44  of the sub-roof  40  is joined via the rivets  60  and the brackets  46  to the upper reinforcement  36 F of the roof reinforcement  30 F, and the second joining portion  58  of the inner layer  56  is joined to the upper reinforcement  36 F of the roof reinforcement  30 F. Therefore, the main roof  50  disposed at the roof  12  of the vehicle may be made more stable (may be fixed in a more stable state) than if the second joining portion  58  of the inner layer  56  was not joined to the upper reinforcement  36 F of the roof reinforcement  30 F. 
     The support portion  44  of the sub-roof  40  is joined by the rivets  60  to the brackets  46  that are integrally attached to the upper face of the upper reinforcement  36 F of the roof reinforcement  30 F, and the first joining portion  54  of the outer layer  52  is joined to the support portion  44  of the sub-roof  40 , including the head portions  62  of these rivets  60  and the peripheries of the head portions  62 . 
     That is, gaps between the peripheries of the head portions  62  of the rivets  60  and the upper face of the support portion  44  are filled by the first adhesive G 1 . As a result, ingression of water into a vehicle cabin through the penetrating holes  44 A and  47 A, in which the shaft portions  64  of the rivets  60  are inserted, may be prevented by the first adhesive G 1 . 
     Furthermore, gaps between the outer edge  52 B of the peripheral edge portion  52 A of the outer layer  52  and, respectively, the upper face of the step portion  42  of the sub-roof  40 , the upper faces of the step portions  16  of the left and right side member outers  14 , and the upper face of the upper reinforcement of the roof reinforcement  30 C at the middle side are sealed up by the sealer S. 
     That is, the sealer S is provided in an annular shape along the outer edge  52 B and has a high coefficient of extension. Therefore, for example, even if the outer edge  52 B thermally expands to the front side and rear side due to a difference in coefficients of linear expansion with a temperature change, this expansion may be adapted to. As a result, ingression of water into the vehicle cabin through, for example, a gap between the outer edge  52 B and the upper face of the step portion  42  of the sub-roof  40  may be prevented. 
     Because the outer layer  52  of each main roof  50  according to the present exemplary embodiment is fabricated of resin, the vehicle may be reduced in weight compared to a structure in which the outer layer  52  is fabricated of metal. Because the inner layer  56  of each main roof  50  according to the present exemplary embodiment is a foam molded body and is formed to be thicker than the outer layer  52 , intrusion of noise into the vehicle cabin may be suppressed effectively and thermal insulation effects may be improved. 
     Because each main roof  50  according to the present exemplary embodiment is integrally provided with the inner layer  56  at the outer layer  52  that structures a roof panel, reference parts (not shown in the drawings) that serve as reference points during assembly may be specified more easily than in a structure in which an inner layer is integrally provided at a roof headlining and attached to a roof panel. 
     That is, when an inner layer is integrally provided at a roof headlining and attached to a roof panel, reference parts are subject to constraint in that the reference parts must be provided at outer periphery portions to be visible. In contrast, the present exemplary embodiment is not subject to this constraint. Moreover, when a wire harness (not shown in the drawings) or the like that is routed between the roof panel and a roof headlining is to be replaced, the main roofs  50  may be detached and the wire harness replaced. Therefore, replacement costs may be lower than when a roof headlining is detached to replace a wire harness or the like. 
     The resin roof  10  (the main roofs  50  and the sub-roofs  40 ) according to the present exemplary embodiment is described above in accordance with the drawings, but the resin roof  10  according to the present exemplary embodiment is not limited by the illustrated structures; suitable design modifications may be applied within a scope not departing from the gist of the present disclosure. For example, the support portion  44  of each sub-roof  40  may be joined to the upper walls  47  of the brackets  46  by an adhesive rather than the rivets  60 . 
     Further, the sub-roof  40  need not be fabricated of a resin that is harder than the outer layer  52  of the main roof  50 . That is, provided the operational effects described above are obtained, the sub-roof  40  may be formed of, for example, the same resin material as the outer layer  52  of the main roof  50  (in the example of the present exemplary embodiment, AES or the like).