JP2004058910A

JP2004058910A - Convertible top structure and its manufacturing method

Info

Publication number: JP2004058910A
Application number: JP2002222474A
Authority: JP
Inventors: Tomoaki Matsunobu; 松延　知昭; Takeshi Hatanaka; 畠中　威
Original assignee: Mazda Motor Corp
Current assignee: Mazda Motor Corp
Priority date: 2002-07-31
Filing date: 2002-07-31
Publication date: 2004-02-26

Abstract

<P>PROBLEM TO BE SOLVED: To provide a convertible top structure and its manufacturing method enabling free selection of a sheet material while suppressing manufacturing cost. <P>SOLUTION: This convertible top structure is provided with a window plate 3 made of a transparent material, a first sheet member 4 having an opening fringe 4a having substantially same or similar shape as a shape of an outer peripheral fringe of the window plate 3, a connection element 6 made of synthetic resin and formed into a long shape along the outer peripheral fringe 3a of the window plate 3 between the vicinity of the outer peripheral fringe 3a of the window plate 3 and the vicinity of the opening fringe 4a of the first sheet member 4, a first fixing means 32 fixing the vicinity of the outer peripheral fringe 3a of the window plate 3 and the connection element 6, and a second fixing means 33 fixing the vicinity of the opening fringe 4a of the first sheet member 4 and the connection element 6. The first sheet member 4 is fixed in such a way that an outer peripheral fringe side 4b has such predetermined width that allows sewing for the connection element 6. A second folding sheet member 5 constituting a convertible top outer surface is sewn by a sewing thread 7 in the first sheet member 4. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本願発明は、自動車の上部後方に設けられたコンバーチブルトップの構造及び、その製造方法に関し、具体的には、コンバーチブルトップに設けられた透明な窓板とその近傍のシート材の構造及び、製造方法に関する。
【０００２】
【従来の技術】
従来の自動車のコンバーチブルトップの構造を示す断面図である図９に示すように、本願出願人は、過去に特開平１１−２８９３５号公報に示すコンバーチブルトップの構造及び、その製造方法を出願した。
【０００３】
このものは、透明な窓板１０３と、該窓板１０３と相似形状の開口縁１０４ａを有する折り畳み可能なシート材１０４との間に沿って、これら窓板１０３とシート材１０４とを連結する合成樹脂製の連結要素１０６が横断面形状異形に形成されるコンバーチブルトップの構造である。
【０００４】
具体的には、シート材１０４が、織物布１０４ｄの車外側用面を、防水性を有する微細なエンボス加工を施した軟質の樹脂シート材１０４ｃでラミネートした構成とされ、該樹脂シート材１０４ｃは前記連結要素１０６の合成樹脂と相溶性を有するものであり、前記連結要素１０６を成形型のキャビティ内で形成する際に、その熱や圧力を利用して前記連結要素１０６を、前記窓板１０３に固着させると共に、シート材１０４の樹脂シート材１０４ｃと溶着させることで、連結要素１０６の横断面形状に影響されること無く前記窓板１０３とシート材１０４とを十分な強度で固着できるコンバーチブルトップの構造及び、この構造を簡単に製造できる製造方法を提供するものである。
なお、連結要素は合成樹脂で出来ているので、その弾性によって窓板３とシート材１０４との間に加わる応力を吸収して夫々が剥離することを防止している。
【０００５】しかしながら、前記軟質の樹脂シート材１０４は、例えばその両面が布地のキャンバス材に比して耐久性や質感が低く、さらに長期間にわたり使用している間にエンボス加工が擦れてしまい、シート材表面の質感が悪化する問題があった。
【０００６】そこで、この問題を解決すべくシート材を変更すると、例えば両面が布地であるキャンバス材の場合は、その表面が布地であることから、既存のシート材の構造に比して連結要素との相溶性が乏しいため連結要素形成時に該連結要素と溶着しにくく、また接着剤層を介して固着しても十分な強度で固着されないので、窓板や連結要素の材質や構造、及びこれに対応した製造設備の変更によるコストがかかる問題があった。また既存の構造と同様の固着手段を用いるようにすると、シート材の選択自由度が低かった。
【０００７】
【発明が解決しようとする課題】
本願発明は前記の問題に鑑みてなされたもので、その課題とするところは、既存の構造及びその製造方法からの変更を最低限としてコスト増加を抑えながら、シート材を自由に選択してデザインや性能の自由度を向上できるコンバーチブルトップの構造及び、その製造方法を提供することにある。
【０００８】
【課題を解決するための手段】
本願発明の第１の構成は、透明な材料からなり表裏両面及び所定の外周面形状を有する窓板と、前記窓板の外周縁形状とほぼ同一又は相似形状の開口縁を有し該窓板よりも柔軟な材料から成る第１のシート材と、前記窓板と第１のシート材とを連結して一体化するため、前記窓板の外周縁近傍と前記第１のシート材の開口縁近傍との間に前記窓板の外周縁に沿って長尺に形成された合成樹脂製連結要素と、前記窓板の外周縁近傍と前記連結要素とを固着する第１の固着手段と、前記第１のシート材の開口縁近傍と前記連結要素とを固着する第２の固着手段と、を備えるものであって、
前記第１のシート材が、前記連結要素に対してその外周縁側が縫製可能な所定の幅を持つよう固着され、
該第１のシート材に、該窓板よりも柔軟な材料から成り、コンバーチブルトップ外表面の少なくとも一部を構成する折り畳み可能な第２のシート材を、縫製糸にて縫製して成ることを特徴とするものである。
【０００９】本構成によれば、第１のシート材と連結要素とは、既存の製造方法によって十分な強度で固着され、かつ第１のシート材と第２のシート材とは、縫製によって第２のシート材の材質に影響されること無く強固に結合されるので、既存の構造からの変更を抑えながらシート材を自由に選択でき、デザインの自由度を向上させることができる。
【００１０】本願発明の第２の構成は、前記第１の構成に記載のコンバーチブルトップの構造において、前記連結要素が、前記窓板の外周縁近傍と前記第１のシート材の開口縁近傍との間に横断面形状異形で前記窓板の外周縁に沿って長尺に形成されたものであって、
前記連結要素は、該連結要素を成形する成形型のキャビティ内にて圧縮された状態で充填され固化してなる合成樹脂により形成されると共に、前記窓板の外周縁近傍に対して、前記キャビティ内にて前記第１の固着手段により固着され、さらに前記第１のシート材の開口縁近傍に対して前記第２の固着手段により固着されて成ることを特徴とするものである。
【００１１】本構成によれば、横断面形状異形の連結要素と十分な強度で固着される第１のシート材に第２のシート材を縫製するので、連結要素の薄肉化や意匠性を向上させつつコンバーチブルトップの強度を十分に高めることができる。
【００１２】本願発明の第３の構成は、前記第１又は第２の構成に記載のコンバーチブルトップの構造において、前記第１のシート材と第２のシート材とが防水性の接着剤にて接合された後、縫製されることを特徴とするものである。
【００１３】本構成によれば、第１のシート材と第２のシート材との接合強度と防水性を向上することができる。
【００１４】本願発明の第４の構成は、前記第１乃至３の何れか１つの構成に記載のコンバーチブルトップの構造において、前記第１のシート材と第２のシート材との縫製部の車室内側にシールテープが貼り付けられていることを特徴とするものである。
【００１５】本構成によれば、第１のシート材と第２のシート材との縫製部における防水性を向上することができる。
【００１６】本願発明の第５の構成は、前記第１乃至第４の何れか１つの構成に記載のコンバーチブルトップの構造において、前記第２のシート材が、前記第１のシート材を車外側から覆い被さるように縫製されていることを特徴とするものである。
【００１７】本構成によれば、第１のシート材が第２のシート材により外側から覆われる為、既存の構造より意匠性や耐候性が向上する。
【００１８】本願発明の第６の構成は、前記第１乃至第５の何れか１つの構成に記載のコンバーチブルトップの構造において、前記第２のシート材は、その両面が布地のキャンバス材であることを特徴とするものである。
【００１９】本構成によれば、シート材の質感や耐久性の高いコンバーチブルトップの構造を提供することができる。
【００２０】本願発明の第７の構成は、前記第６の構成に記載のコンバーチブルトップの構造において、前記第２のシート材は、車外側に面する合成繊維製織物布からなる表地と、車室内側に面する自然繊維製織物布からなる裏地と、これら表地と裏地とに挟まれた防水性材料からなる中間材とから構成されることを特徴とするものである。
【００２１】本構成によれば、車外側は耐候性の高い合成繊維製布によって質感の耐久性を高めつつ中間材によって防水性を確保し、車室内側は質感や手触り感を良好とすることができる。
【００２２】本願発明の第８の構成は、透明な材料からなり表裏両面及び所定の外周面形状を有する窓板と、前記窓板の外周縁形状とほぼ同一又は相似形状の開口縁を有し該窓板よりも柔軟な材料から成る第１のシート材と、前記窓板と第１のシート材とを連結して一体化するために、前記窓板の外周縁近傍と前記第１のシート材の開口縁近傍との間に前記窓板の外周縁に沿って長尺に形成された合成樹脂製連結要素と、前記窓板の外周縁近傍と前記連結要素とを固着する第１の固着手段と、前記第１のシート材の開口縁近傍と前記連結要素とを固着する第２の固着手段と、を備えるコンバーチブルトップの製造方法であって、
前記連結要素を、前記第１の固着手段によって前記窓板の外周縁近傍と固着させる工程と、前記連結要素を、前記第２の固着手段によって前記第１のシート材と固着させる工程と、
前記窓板の外周縁近傍に対して固着された前記第１のシート材の外周縁側が縫製可能な所定の幅を持つよう前記第１のシート材を整形する工程と、該第１のシート材の縁部に、該窓板よりも柔軟な材料から成り、コンバーチブルトップ外表面の少なくとも一部を構成する折り畳み可能な第２のシート材を縫製糸にて縫製する工程とを具備することを特徴とするものである。
【００２３】本構成によれば、既存の製造方法に、第１のシート材の外周縁側を所定分残して切り取る工程と、第２のシート材を第１のシート材に縫製する工程を追加するのみで、第２のシート材の材質に影響されること無く、前記第１の構成に記載されたコンバーチブルトップの構造を製造でき、製造コスト増加を抑えながら、シート材を自由に選択できデザインの自由度を向上できる。
【００２４】本願発明の第９の構成は、透明な材料からなり表裏両面及び所定の外周面形状を有する窓板と、前記窓板の外周縁形状とほぼ同一又は相似形状の開口縁を有し該窓板よりも柔軟な材料から成る第１のシート材と、前記窓板と第１のシート材とを連結して一体化するために、前記窓板の外周縁近傍と前記第１のシート材の開口縁近傍との間に横断面形状異形で前記窓板の外周縁に沿って長尺に形成された合成樹脂製連結要素と、前記窓板の外周縁近傍と前記連結要素とを固着する第１の固着手段と、前記第１のシート材の開口縁近傍と前記連結要素とを固着する第２の固着手段と、を備えるコンバーチブルトップの製造方法であって、
前記連結要素を、該連結要素を成形する成形型のキャビティ内にて圧縮された状態で充填して固化させてなる合成樹脂により形成し、この際に前記第１の固着手段によって前記窓板の外周縁近傍と固着させると共に、前記第２の固着手段によって前記第１のシート材と固着させる工程と、
前記第１のシート材の外周縁側を縫製可能な所定の幅を持つよう切り取る工程と、該第１のシート材の縁部に、該窓板よりも柔軟な材料から成り、コンバーチブルトップ外表面の少なくとも一部を構成する折り畳み可能な第２のシート材を縫製糸にて縫製する工程とを具備することを特徴とするものである。
【００２５】本構成によれば、横断面形状異形の連結要素と第１のシートとを簡単に接着可能な既存の製造方法に、第１のシート材の外周縁側を所定分残して切り取る工程と、第２のシート材を第１のシート材に縫製する工程を追加するのみで、前記第８の構成同様、第２のシート材の材質に影響されること無く、前記第１の構成に記載されたコンバーチブルトップの構造を製造でき、製造コスト増加を抑えながら、シート材を自由に選択でき、デザインの自由度を向上できる。
【００２６】本願発明の第１０の構成は、前記本願発明の第８又は第９の構成に記載のコンバーチブルトップの製造方法において、前記第１のシート材と第２のシート材とを、縫製する前に防水性の接着剤にて接合する工程を具備することを特徴とするものである。
【００２７】本構成によれば、前記第３の構成に記載されたコンバーチブルトップの構造を製造でき、前記第１のシート材と第２のシート材との接合強度と防水性を向上することができると共に、各シート材を縫製前に接合することで縫製時に各シート材を位置決めする必要が無く縫製が正確かつ容易となる。
【００２８】本願発明の第１１の構成は、前記本願発明の第８乃至第１０の何れか１つの構成に記載のコンバーチブルトップの製造方法において、前記第１のシート材と第２のシート材との縫製部の車室内側にシールテープを貼り付ける工程を具備することを特徴とするものである。
【００２９】本構成によれば、前記第４の構成に記載されたコンバーチブルトップの構造を製造でき、第１のシート材と第２のシート材との縫製部の防水性を向上することができる。
【００３０】本願発明の第１２の構成は、前記本願発明の第８乃至第１１の何れか一つに記載のコンバーチブルトップの製造方法において、前記第２のシート材を、前記第１のシート材に車外側から覆い被せて縫製する工程を具備することを特徴とするものである。
【００３１】本構成によれば、前記第５の構成に記載されたコンバーチブルトップを製造することができ、既存の構造より意匠性や耐候性を向上させることができる。
【００３２】
【発明の効果】
本願発明によれば、既存の構造及びその製造方法からの変更を抑えながら、シート材を自由に選択でき、デザインの自由度を向上できるコンバーチブルトップの構造及び、その製造方法を提供できる。
【００３３】
【発明の実施の形態】以下に、本願発明の第１の実施形態を、図面に基づいて説明する。
図１は本願発明によるコンバーチブルトップの使用状況を示した斜視図であり、図２はコンバーチブルトップに取り付けられた窓板近傍の拡大図、図３は図２における線Ａ−Ａ矢視断面図である。
また、図４は、（ａ）が第１のシート材の積層構造を示し、（ｂ）が第２のシート材の積層構造を示す模式図である。
【００３４】図１、図２に示すように、車両１には、使用時において、その車室後方から前方へ延びるコンバーチブルトップ２が設けられている。
該コンバーチブルトップ２は、車体後部に強化ガラス製の窓板３が取り付けられると共に、その他の部分が窓板３より柔軟な材料からなる第１のシート材４及び、折り畳み可能な第２のシート材５により覆われており、前記窓板３は、第１のシート材４に連結要素である枠部材６を介して取り付けられた構造の折り畳み可能なキャンバストップまたはソフトトップである。
【００３５】コンバーチブルトップ２を使用する時は、図１に示すように、シート材４、５が張設されて車両１の車室上部を覆う幌屋根を形成し、使用しないときは、図示しないが後方に折り畳むことで、前記幌屋根を開放したオープンカーとすることができる。
【００３６】また、このような窓板が取り付けられた幌構造としては、前記オープンカーに限らず、四輪駆動車や一部のスポーツユーティリティ車の幌部分に側面窓が設けられたもの、及び建築・土木作業車、農業用車両等の幌部分に窓が設けられたものにも適用することができ、これらを含めてコンバーチブルトップと称する。
【００３７】本実施形態では、窓板３に、無機ガラスに熱処理を施して強度を高めた強化ガラスを用いているが、これに限らず透明でかつシート材４、５より剛性が高く自己保形成のある材質であればよい。例えば合わせガラスや、ポリカーボネートの様な透明な合成樹脂製の板材でも良い。
【００３８】次に、本願発明によるコンバーチブルトップの構造の第１実施形態を、枠部材６の断面形状から詳細に説明する。なお、これ以下、総ての実施形態に関しては、窓面に沿って窓板の中心に向かう方向を内向き、窓面に沿って窓板の中心から放射状に広がる方向を外向きとし、これらの向きに合わせてそれぞれ内周縁と外周縁を定義する。
【００３９】図３及び図４（ａ）に示すように、第１のシート材４は、前記窓板３の外周縁３ａに沿って配設され、その構造は既存の構造と同じくされており、コンバーチブルトップ使用時に車室外側に面する表地が軟質ＰＶＣ（ポリ塩化ビニル）から成る樹脂シート材４ｃ、裏地が綿の織物布から成る布製シート材４ｄで構成され、窓板３よりも柔軟に設定されている。
また、その中央部には窓板３の外周縁３ａとほぼ同一形状の開口縁４ａが形成されている。
【００４０】枠部材６は、窓板３の外周縁３ａと第１のシート材４の開口縁４ａとの間に設けられ、後述する枠部材の射出成形型２０によって形成されたキャビティ２３に、窓板３の外周縁３ａと第１のシート材４の開口縁４ａとを介在させた状態で、液状の熱可塑性合成樹脂を加熱圧縮した状態で充填し、そのまま冷却してキャビティ２３内で固化させ、窓板３の外周縁３ａに沿って長尺に形成されたものであって、窓板３と第１のシート材４とを連結している。
なお、枠部材６の材料としては、前記熱可塑性樹脂に限らず、反応して合成樹脂を形成する液状の樹脂原料でも良い。
また、図２に示すように、コンバーチブルトップ２使用中は、枠部材６のアッパー部６ａに第１のシート材４からの張力と窓板３の自重による影響でロアー部６ｂより大きな引っ張り応力を受けるので、アッパー部６ａの窓板３と第１のシート材４との接触面積を他の部分より大きくし、アッパー部６ａが受ける引っ張り応力を軽減させることが好ましい。
【００４１】前記第１のシート材４は、枠部材６との固着部分より更に外側に、第２のシート材５と縫製されるための縫製代４ｂを有している。
そして、第２のシート材５は、窓板３の外周縁３ａより一回り大きな相似形状で、かつ第１のシート材４の縫製代４ｂより小さな開口縁５ａを有しており、図３に示すように、その開口縁５ａにおいて端部を車室内側に折り曲げた状態で接着剤層１０によって接着された縫製代５ｂが形成されていると共に、その車室側面も接着剤層１１によって第１のシート材４の縫製代４ｂと接着されており、第１のシート材４の縫製代４ｂと第２のシート材５の縫製代５ｂとの重なる部分が、縫製糸７にて縫製されて縫製部８が形成されている。
これにより、縫製部８において第１のシート材４と第２のシート材５との間から雨水が車室内へ染み込むのを防止できると共に、縫製によってシート材４、５の材質に関係無く十分な固着強度を得ることができる。
【００４２】さらに、第１のシート材４の縫製代４ｂには、その車室内側に防水性のシールテープ１２が貼り付けられ、縫製部を隠して見栄えを良くすると共に、縫製部分から雨水が車室内に浸入することを防止するようになっている。上述のように、本実施形態においては、第１のシート材４に第２のシート材５を縫製することで、第１のシート材４を枠部材６と既存の方法にて固着可能な材質とし、第２のシート材５の材質を自由に選べるので、構造や製造方法の変更を最小限としてコスト上昇を抑えながらコンバーチブルトップ２のデザインの自由度を向上できるものである。
【００４３】なお、図４（ｂ）に示すように第２のシート材５は、コンバーチブルトップ２使用時に車室外側に面する表地５ｃが、耐候性の高い合成繊維（例えばアクリル繊維）の平織物布、裏地５ｄが質感や手触り感の良い綿の織物布、そしてその中間材５ｅとして、防水性を有する合成ゴムが積層された構成とされ、窓板３よりも柔軟に設定されている。
【００４４】次に、本願発明のコンバーチブルトップの製造方法及び装置を、図を参照して工程順に説明する。
図５乃至７は本願発明のコンバーチブルトップの製造方法及び装置の実施形態であって、図３に記載の枠部材を製造する際の一工程を示したものであり、図５は、枠部材成形型であるコア型及びキャビティ型を、窓板と第１のシート材とを挟みこんで型締めした工程を示す断面図、図６は、枠部材成形型であるコア型及びキャビティ型を閉じた状態で枠部材となる合成樹脂をキャビティに注入した工程を示す断面図、図７は、成形型から取り出したコンバーチブルトップの第１のシート材を、不用部分をトリムして整形する工程を示す断面図である。
なお、図１乃至４と同一部分には同一符号を用い詳細な説明は省略する。
【００４５】本実施形態におけるコンバーチブルトップ２の製造装置は、図示しないダイプレート上に、分割面で分割可能なスチール製の射出成形型２０を構成する、一方のモールドハーフのコア型２１と、他方のモールドハーフのキャビティ型２２とを有し、これらの分割面２１０、２２０間に窓板３と第１のシート４とを挟んだ状態で液状の合成樹脂を射出充填して枠部材６を成形するキャビティ２３を形成する。
これにより、枠部材６を射出成形すると共に、枠部材６により窓板３と第１のシート材４とを一体に連結するものである。
【００４６】コア型２１は、その分割面２１０にキャビティ２３を形成する型面２１１を有すると共に、窓板３の面中央部に窓板３との接触防止用の逃げ凹部２１２を有する。
そして、分割面２１０には、枠部材６成形時に第１のシート材４を位置決めする為の位置決めピン２４が設けられており、該位置決めピン２４は図示上方へ向けてコンプレッションスプリング２５によって窓板３側に付勢され、予め第１のシート材４に穿たれた位置決め孔４ｅに嵌合して、これを固定するようになっている。この位置決めピン２４は、直接窓板３の表面を押圧するから、窓板３よりも軟質で耐磨耗性のある材質（例えばポリアセタール樹脂）が好ましい。
また、逃げ凹部２１２には、窓板３を位置決め固定するためのバキューム吸盤２６が設けられ、このバキューム吸盤２６を、図示しない真空ポンプに吸引管２７を介して接続している。
【００４７】キャビティ型２２の上面にはランナープレート２８が重ね合わされており、ランナープレート２８との合わせ面には、図示しない射出成形機の射出ノズルから供給される合成樹脂の樹脂流路であるランナー２９が形成されると共に、キャビティ型２２には、ランナー２９の途中にキャビティ２３と連通するスプルー３０及びキャビティ２３に面するピンポイント式の射出ゲート３０ａを有している。
図７の参照符号３１は、射出成形により枠部材６と一体化した第１のシート材４に切れ目を入れ、不要部４００をトリムして整形するためのカッターである。
なお、前記成形型２０は既存のコンバーチブルトップを製造する成形型と同一構造とすることが可能である。
【００４８】次に、図５乃至７を用いて、本実施形態におけるコンバーチブルトップの製造方法を工程順に説明する。
まず、前準備として第１のシート材４の内側の不用部４００に位置決め孔４ｅを穿っておく。
そして、第１工程では、図５に示すように、位置決め孔４ｅの位置を位置決めピン２４に合うように第１のシート材４をコア型２１に固定し、その上に窓板３を、その外周縁３ａがキャビティ２３の所定位置になるよう配置すると共に、バキューム吸盤２６によって固定した状態で、キャビティ型２２をコア型２１の上に載せて成形型２０を型締めする。
【００４９】なお、窓板３の外周縁３ａには、予め第１の固着手段である接着剤層３２を形成しておく。また、窓板３は、枠部材６が形成されるまでは、常温以上に加熱膨張させておくことが好ましい。これにより、枠部材６成形プロセス中の冷却、固化に伴ない窓板３に対して生じる枠部材６からの内部応力を緩和し、窓板３の変形や破損を防止できる。
【００５０】第２工程では、図６に示すように、コア型２１の第１のシート４により覆われた型面２１１と、これに対応するキャビティ型２２の型面２２１並びに片持ち状態に固定された窓板３の外周縁３ａ近傍表面とにより形成されるキャビティ２３に、液状の合成樹脂を射出して射出成形を行う。
つまり、射出成形は、キャビティ２３に、スプルー３０の射出ゲート３０ａから加熱溶融された液状の熱可塑製合成樹脂を射出することにより行う。但し、射出ゲート３０ａの位置や射出方向は、射出された合成樹脂が直接窓板３に当たらないように設定するのが好ましい。これにより、射出された液状合成樹脂の圧力を窓板３が受けることがなく、窓板３の変形や割れを防止できる。
【００５１】本実施例における液状合成樹脂は、軟質ＰＶＣの様な熱可塑製合成樹脂であって、加熱により軟化して流動可能状態となり、冷却によって固化する。
このように、窓板３と第１のシート材４とを枠部材６により一体化することができる。なお、この工程を以下に詳述する。
【００５２】図５及び６に示すように、コア型２１とキャビティ型２２との分割面２１０、２２０に、窓板３と第１のシート材４とを挟んだ状態で型締めすると、成形型２０の内部にキャビティ２３が形成される。このキャビティ２３は、コア型２１の型面２１１に密着した第１のシート材４と、キャビティ型２２の型面２２１との両型面間に片持ち状態で位置する窓板３の外周縁３ａ近傍表面とで形成され、窓板３の長手方向に沿って延在し形成すべき所望の枠部材６の形状に対応している。この状態で、スプルー３０を介して射出ゲート３０ａから加熱溶融された液状の熱可塑製の合成樹脂を射出する。
【００５３】この時、図６に示すように、窓板３の外周縁３ａよりもやや外向きに実線で示した射出ゲート３０ａから射出された合成樹脂は、キャビティ２３内に突出した片持ち状態の窓板３に直接衝突しないので、窓板３に曲げモーメントを発生させることはない。従って、窓板３が無機ガラスのときには破損や割れを防ぎ、合成樹脂のときには変形を防止できる。
【００５４】図６に示すように、射出された合成樹脂は、第１のシート材４及びその裏に位置するコア型２１の型面２１１に衝突して、まず射出ゲート３０ａの付近に充填されてその後キャビティ２３の長手方向に流動して行き全体を埋める。
合成樹脂が射出及び流動する際、第１のシート材４の樹脂シート材４ｃは、溶融した合成樹脂の熱で過熱されて幾分軟化し、かつ射出された合成樹脂のキャビティ２３内における圧力で伸びてコア型２１の型面２１１に押し付けられ、型面２１１に沿った形状に形成される。これにより、枠部材６が形成されると共に、枠部材６の表面に第１のシート材４が積層一体化される。
【００５５】一方、窓板３と枠部材６とは、枠部材６を形成する液状の合成樹脂の熱と射出圧力が作用して、第１の固着手段である接着剤層３２を活性化し、窓板３の外周縁３ａ近傍の表面と枠部材６とは強固に固着される。なお、窓板３として無機ガラスを、枠部材として軟質又は半硬質のＰＶＣ樹脂を使用するときには、第１の固着手段としての接着剤は、アクリル変性・フェノール樹脂を主体とした接着剤を使用できる。
【００５６】第１のシート材４の樹脂シート材４ｃが、射出される合成樹脂と相溶性を有するときには、射出された合成樹脂の伝導熱で樹脂シート材４ｃの表面が幾分溶融し、枠部材６を形成する合成樹脂と溶け合うと共に、射出された合成樹脂の圧力が作用して溶着部３３を形成し、固着を強固なものにする。この場合には、前記溶着部３３が第２の固着手段となる。なお、枠部材６を形成する合成樹脂として、軟質のＰＶＣを使用するときには、射出される樹脂の温度を２００℃〜２２０℃程度に加熱させるのが好ましい。
【００５７】枠部材６が形成される部分の第１のシート材４に、第２の固着手段として前記第１の固着手段と同様の接着剤層が予め形成されているものでは、この接着剤と、射出された合成樹脂からの伝導熱と圧力との相乗作用で接着し、この時もまた強固な固着が得られる。なお、この工程までは既存の製造工程と共通である。
【００５８】第３工程では、枠部材６が形成されたコンバーチブルトップ２の中間体を成形型２０から取り出して鋭利な刃を有するカッター３１によって第１のシート材４の不用部４００をトリムして整形する。この際、第１のシート材４の内周縁側は形成された枠部材６の内周縁６ｄに沿ってトリムし、外周縁側は、後述する第２のシート材５と縫製するための縫製代４ｂとして、枠部材６の外周縁６ｃから所定の幅を確保してトリムする。なお、窓板３をカッター３１によって損傷させる可能性がある場合は、手動又は電動の鋏を用いても良い。
【００５９】第４の工程では、図３に示すように、予め第２のシート材５の開口縁近傍の車室内側面に接着剤層１０を形成して、その端部を車室内側に織り返した状態に接着しておき、第１のシート材４の縫製代４ｂも車外側面に接着剤層１１を形成しておく。
そして、第２のシート材５の縫製代５ｂを第１のシート材４の縫製代４ｂに車外側から重ね合わせた状態で両シート材４、５を縫製糸７を用いて縫製した後、この縫製部の第１のシート材４車室内側にシールテープ１２を貼り付ける。
これにより、第１のシート材４と第２のシート材５とが強固に固着され、両シート材間や縫製部から車室内に雨水が浸入することを防ぐことができる。
【００６０】図８は本願発明の第２の実施形態における図３に相当する断面図であり、共通する部分には同一の符号を付け詳細な説明は省略する。図８に示すように、第２のシート材５の開口縁５ａを枠部材６の内周縁６ｄ近傍まで延長し、前記実施形態同様に第１のシート材４の縫製代４ｂと第２のシート材５の縫製代５ｂとを縫製及び接着すると共に、第２のシート材５の縫製部８より内周縁側を枠部材６の車外側面と接着する構成としている。
これにより、第１のシート材４及び枠部材６が、第２のシート材５によって車外に対して覆われるので、コンバーチブルトップ２の外観が第２のシート材５により統一されて質感が向上する。また、第１のシート材４や枠部材６が直射日光や風雨に曝されることが無く、これらに耐候性の低い材質を使用することができる。
【００６１】以上の様な構成によって、本願発明を適用した車両においては、コンバーチブルトップの構造及びその製造方法を、既存の構成に対して第１のシート材４の外周縁に縫製代４ｂを設けて整形し、第１のシート材４と第２のシート材５とを縫製する構成を追加するだけで、コンバーチブルトップのシート材を自由に選択でき、デザインの自由度を向上させると共に、既存の構造の製造方法と工程が途中まで共通の為、既存の製造設備をそのまま利用でき、既存の構造との混流生産も可能であるので製造コストを抑えることができる。
【図面の簡単な説明】
【図１】本願発明の第１の実施形態におけるコンバーチブルトップの後方斜視図である。
【図２】本願発明の第１の実施形態における窓板近傍の拡大図である。
【図３】本願発明の第１の実施形態における窓板近傍の図２に示す線Ａ−Ａ矢視断面図である。
【図４】本願発明の第１及び第２シート材の積層構造を示す模式図である。
【図５】本願発明の第１の実施形態における枠部材形成時の１工程を示す断面図である。
【図６】本願発明の第１の実施形態における枠部材形成時の１工程を示す断面図である。
【図７】本願発明の第１の実施形態における枠部材形成時の１工程を示す断面図である。
【図８】本願発明の第２の実施形態における窓板近傍の図２に示す線Ａ−Ａ矢視断面図である。
【図９】図３に相当する従来のコンバーチブルトップの断面図である。
【符号の説明】
１・・・車両
２・・・コンバーチブルトップ
３・・・窓板
４・・・第１のシート材
５・・・第２のシート材
６・・・枠部材
７・・・縫製糸
８・・・縫製部
１１・・・接着剤層（第１のシート材と第２のシート材接着用）
１２・・・シールテープ
２０・・・成形型
２３・・・キャビティ
３２・・・接着剤層（第１の固着手段）
３３・・・溶着部（第２の固着手段）[0001]
TECHNICAL FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structure of a convertible top provided on an upper rear portion of an automobile and a method of manufacturing the same, and more specifically, a structure of a transparent window plate provided on the convertible top and a sheet material in the vicinity thereof, and a method of manufacturing the same. About.
[0002]
[Prior art]
As shown in FIG. 9 which is a cross-sectional view showing the structure of a conventional convertible top of an automobile, the applicant of the present application has previously filed an application for the structure of a convertible top disclosed in Japanese Unexamined Patent Application Publication No. 11-28935 and its manufacturing method.
[0003]
This is a composite that connects the window plate 103 and the sheet material 104 along a transparent window plate 103 and a foldable sheet material 104 having an opening edge 104a similar in shape to the window plate 103. This is a convertible top structure in which a resin-made connecting element 106 is formed in an irregular cross-sectional shape.
[0004]
Specifically, the sheet material 104 has a structure in which a vehicle exterior surface of a woven fabric 104d is laminated with a soft resin sheet material 104c that has been subjected to fine waterproof embossing, and the resin sheet material 104c is The connection element 106 is compatible with the synthetic resin of the connection element 106. When the connection element 106 is formed in the cavity of the mold, the connection element 106 is formed by utilizing the heat and pressure. And by welding the sheet material 104 to the resin sheet material 104c so that the window plate 103 and the sheet material 104 can be fixed with sufficient strength without being affected by the cross-sectional shape of the connecting element 106. And a manufacturing method that can easily manufacture this structure.
Since the connecting elements are made of synthetic resin, the elasticity of the connecting elements absorbs the stress applied between the window plate 3 and the sheet material 104, thereby preventing each of the connecting elements from peeling off.
[0005] However, the soft resin sheet material 104 has low durability and texture on both sides, for example, as compared with the canvas material of the fabric, and the embossing is rubbed during long-term use. There was a problem that the texture of the sheet material surface deteriorated.
Therefore, when the sheet material is changed to solve this problem, for example, in the case of a canvas material in which both sides are made of fabric, since the surface thereof is made of fabric, the connecting elements are more compared with those of the existing sheet material. Is poorly compatible with the connecting element at the time of forming the connecting element due to poor compatibility, and is not fixed with sufficient strength even when fixed via an adhesive layer, so that the material and structure of the window plate and the connecting element, and However, there is a problem that the cost is increased due to the change of the manufacturing equipment corresponding to the above. When the same fixing means as that of the existing structure is used, the degree of freedom in selecting the sheet material is low.
[0007]
[Problems to be solved by the invention]
SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object the design of a sheet material by freely selecting a sheet material while minimizing a change from the existing structure and its manufacturing method and suppressing an increase in cost. To provide a structure of a convertible top capable of improving the degree of freedom in performance and performance, and a method of manufacturing the same.
[0008]
[Means for Solving the Problems]
According to a first aspect of the present invention, there is provided a window plate made of a transparent material and having both front and rear surfaces and a predetermined outer peripheral surface shape, and an opening edge substantially identical or similar to the outer peripheral edge shape of the window plate. In order to connect and integrate the first sheet material made of a more flexible material with the window plate and the first sheet material, the vicinity of the outer periphery of the window plate and the opening edge of the first sheet material A synthetic resin connecting element formed long along the outer peripheral edge of the window plate between the vicinity thereof, first fixing means for fixing the connecting element to the vicinity of the outer peripheral edge of the window plate, and Second fixing means for fixing the vicinity of the opening edge of the first sheet material and the connection element,
The first sheet material is fixed to the connection element so that an outer peripheral edge side thereof has a predetermined width capable of being sewn,
A foldable second sheet material made of a material softer than the window plate and constituting at least a part of the convertible top outer surface is sewn to the first sheet material with sewing thread. It is a feature.
According to this configuration, the first sheet material and the connecting element are fixed with sufficient strength by the existing manufacturing method, and the first sheet material and the second sheet material are joined together by sewing. Since the sheet material is firmly connected without being affected by the material of the sheet material 2, the sheet material can be freely selected while suppressing a change from the existing structure, and the degree of freedom in design can be improved.
[0010] In a second structure of the present invention, in the convertible top structure according to the first structure, the connecting element may be located near an outer peripheral edge of the window plate and near an opening edge of the first sheet material. It is formed in a long shape along the outer peripheral edge of the window plate with a cross-sectional shape irregular shape between,
The connecting element is formed of a synthetic resin that is filled and solidified in a compressed state in a cavity of a mold for molding the connecting element, and the cavity is formed near an outer peripheral edge of the window plate. The first sheet member is fixed to the inside of the first sheet member, and is fixed to the vicinity of the opening edge of the first sheet material by the second fixing member.
According to this structure, the second sheet material is sewn on the first sheet material which is fixed with sufficient strength to the connection element having the irregular cross-sectional shape, so that the thickness of the connection element is reduced and the design is improved. The strength of the convertible top can be sufficiently increased while performing this.
According to a third structure of the present invention, in the convertible top structure according to the first or second structure, the first sheet material and the second sheet material are bonded with a waterproof adhesive. It is characterized by being sewn after being joined.
According to this structure, the joining strength between the first sheet material and the second sheet material and waterproofness can be improved.
According to a fourth aspect of the present invention, there is provided a convertible top structure according to any one of the first to third aspects, wherein a sewing portion of the first sheet material and the second sheet material is sewn. The present invention is characterized in that a seal tape is stuck on the indoor side.
According to this configuration, the waterproofness at the sewing portion between the first sheet material and the second sheet material can be improved.
According to a fifth aspect of the present invention, in the convertible top structure according to any one of the first to fourth aspects, the second sheet member is provided on the vehicle exterior side. It is characterized by being sewn so as to cover.
According to this structure, since the first sheet material is covered from the outside by the second sheet material, the design and weather resistance are improved as compared with the existing structure.
According to a sixth aspect of the present invention, in the convertible top structure according to any one of the first to fifth aspects, the second sheet material is a canvas material having a fabric on both sides. It is characterized by the following.
According to this configuration, it is possible to provide a convertible top structure having high texture and durability of the sheet material.
According to a seventh aspect of the present invention, in the convertible top structure according to the sixth aspect, the second sheet material includes a surface material made of a woven fabric made of synthetic fiber facing the outside of the vehicle and a vehicle. It is characterized by comprising a lining made of a woven fabric made of natural fibers facing the indoor side, and an intermediate material made of a waterproof material sandwiched between the outer lining and the lining.
According to this structure, the outer side of the vehicle is made of synthetic fiber cloth having high weather resistance to increase the durability of the texture, while the waterproofness is ensured by the intermediate material, and the interior side of the vehicle is improved in the texture and feel. Can be.
According to an eighth aspect of the present invention, there is provided a window plate made of a transparent material and having both front and rear surfaces and a predetermined outer peripheral surface shape, and an opening edge substantially the same as or similar to the outer peripheral shape of the window plate. A first sheet material made of a material that is more flexible than the window plate, and a first sheet material near the outer periphery of the window plate and the first sheet for connecting and integrating the window plate and the first sheet material; A synthetic resin connecting element elongated along the outer peripheral edge of the window plate between the vicinity of the opening edge of the material and a first fixing unit for fixing the connecting element near the outer peripheral edge of the window plate to the connecting element; Means, and a second fixing means for fixing the vicinity of the opening edge of the first sheet material and the connecting element, the method of manufacturing a convertible top,
Fixing the connecting element to the vicinity of the outer peripheral edge of the window plate by the first fixing means; fixing the connecting element to the first sheet material by the second fixing means;
Shaping the first sheet material so that the outer peripheral edge side of the first sheet material fixed to the vicinity of the outer peripheral edge of the window plate has a predetermined width that can be sewn; Sewing a second foldable sheet material made of a material softer than the window plate and constituting at least a part of the outer surface of the convertible top with a sewing thread. It is assumed that.
According to this configuration, a step of cutting off the outer peripheral side of the first sheet material by a predetermined amount and a step of sewing the second sheet material to the first sheet material are added to the existing manufacturing method. Only with this, the structure of the convertible top described in the first configuration can be manufactured without being affected by the material of the second sheet material, and the sheet material can be freely selected while suppressing an increase in manufacturing cost. The degree of freedom can be improved.
According to a ninth aspect of the present invention, there is provided a window plate made of a transparent material and having both front and rear surfaces and a predetermined outer peripheral surface shape, and an opening edge substantially the same as or similar to the outer peripheral edge shape of the window plate. A first sheet material made of a material that is more flexible than the window plate, and a first sheet material near the outer periphery of the window plate and the first sheet for connecting and integrating the window plate and the first sheet material; A connecting element made of synthetic resin formed along the outer peripheral edge of the window plate with an irregular shape in cross section between the vicinity of the opening edge of the material and the connecting element near the outer peripheral edge of the window plate. A method of manufacturing a convertible top, comprising: a first fixing means for fixing the first sheet material; and a second fixing means for fixing the vicinity of an opening edge of the first sheet material and the connection element.
The connecting element is formed of a synthetic resin that is filled and solidified in a compressed state in a cavity of a mold for molding the connecting element, and at this time, the first fixing unit fixes the window plate. Fixing to the vicinity of the outer periphery and fixing to the first sheet material by the second fixing means;
Cutting the outer peripheral edge of the first sheet material so as to have a predetermined width capable of being sewn; and forming an edge of the first sheet material on the outer surface of the convertible top made of a material softer than the window plate. Sewing a foldable second sheet material constituting at least a part thereof with sewing thread.
According to the present configuration, a step of cutting off the outer peripheral side of the first sheet material by a predetermined amount is provided by an existing manufacturing method capable of easily adhering the connecting element having the irregular cross-sectional shape and the first sheet. According to the first configuration, the second sheet material is sewn to the first sheet material only, and the second sheet material is not affected by the material of the second sheet material as in the eighth configuration. The structure of the converted top can be manufactured, the sheet material can be freely selected, and the degree of freedom of design can be improved while suppressing an increase in manufacturing cost.
According to a tenth aspect of the present invention, in the method for manufacturing a convertible top according to the eighth or ninth aspect of the present invention, the first sheet material and the second sheet material are sewn. The method is characterized in that the method further comprises a step of bonding with a waterproof adhesive before.
According to this structure, the structure of the convertible top described in the third structure can be manufactured, and the joining strength and the waterproofness between the first sheet material and the second sheet material can be improved. In addition, by joining each sheet material before sewing, it is not necessary to position each sheet material at the time of sewing, and sewing can be performed accurately and easily.
According to an eleventh aspect of the present invention, in the method of manufacturing a convertible top according to any one of the eighth to tenth aspects of the present invention, the first sheet material and the second sheet material are The step of attaching a seal tape to the interior side of the sewing portion of the sewing machine.
According to this structure, the structure of the convertible top described in the fourth structure can be manufactured, and the waterproofness of the sewn portion between the first sheet material and the second sheet material can be improved. .
According to a twelfth aspect of the present invention, in the method for manufacturing a convertible top according to any one of the eighth to eleventh aspects of the present invention, the second sheet material is replaced with the first sheet material. And a step of covering and sewing from outside of the vehicle.
According to this configuration, the convertible top described in the fifth configuration can be manufactured, and the design and weather resistance can be improved as compared with the existing structure.
[0032]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the structure of the convertible top which can select a sheet material freely and can improve the degree of freedom of design, and the manufacturing method thereof can be provided, suppressing the change from the existing structure and its manufacturing method.
[0033]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to the drawings.
FIG. 1 is a perspective view showing a use state of a convertible top according to the present invention, FIG. 2 is an enlarged view near a window plate attached to the convertible top, and FIG. 3 is a sectional view taken along line AA in FIG. is there.
FIGS. 4A and 4B are schematic diagrams showing the laminated structure of the first sheet material and FIG. 4B showing the laminated structure of the second sheet material.
As shown in FIGS. 1 and 2, the vehicle 1 is provided with a convertible top 2 extending forward from the rear of the passenger compartment when in use.
The convertible top 2 has a first sheet material 4 having a tempered glass window plate 3 attached to the rear portion of the vehicle body, and other portions made of a material more flexible than the window plate 3, and a foldable second sheet material. The window plate 3 is a foldable canvas top or soft top having a structure attached to the first sheet material 4 via a frame member 6 serving as a connecting element.
When the convertible top 2 is used, as shown in FIG. 1, sheet materials 4 and 5 are stretched to form a hood roof covering the upper part of the cabin of the vehicle 1, and when not used, it is not shown. By folding back, the open car with the roof top open can be obtained.
The hood structure to which such a window plate is attached is not limited to the open car, but has a side window provided on the hood portion of a four-wheel drive vehicle or some sports utility vehicles. It can also be applied to a construction / civil work vehicle, an agricultural vehicle, and the like in which a window is provided in a hood portion, and these are also referred to as a convertible top.
In the present embodiment, the window plate 3 is made of a tempered glass obtained by applying a heat treatment to an inorganic glass to increase the strength. However, the present invention is not limited to this. Any material that can be formed may be used. For example, a laminated glass or a plate made of a transparent synthetic resin such as polycarbonate may be used.
Next, a first embodiment of the structure of the convertible top according to the present invention will be described in detail from the sectional shape of the frame member 6. Hereinafter, for all embodiments, the direction toward the center of the window plate along the window surface is inward, and the direction radially extending from the center of the window plate along the window surface is outward, An inner peripheral edge and an outer peripheral edge are defined according to the directions.
As shown in FIGS. 3 and 4A, the first sheet material 4 is arranged along the outer peripheral edge 3a of the window plate 3, and its structure is the same as the existing structure. When the convertible top is used, the outer material facing the outside of the cabin is made of a resin sheet material 4c made of soft PVC (polyvinyl chloride), and the lining material is made of a cloth sheet material 4d made of a woven cotton cloth, which is more flexible than the window plate 3. Is set.
An opening edge 4a having substantially the same shape as the outer peripheral edge 3a of the window plate 3 is formed at the center thereof.
The frame member 6 is provided between the outer peripheral edge 3a of the window plate 3 and the opening edge 4a of the first sheet material 4, and is provided in a cavity 23 formed by an injection mold 20 of the frame member described later. With the outer peripheral edge 3a of the window plate 3 and the opening edge 4a of the first sheet material 4 interposed therebetween, a liquid thermoplastic synthetic resin is filled in a heated and compressed state, cooled as it is, and solidified in the cavity 23. It is formed long along the outer peripheral edge 3 a of the window plate 3, and connects the window plate 3 and the first sheet material 4.
The material of the frame member 6 is not limited to the thermoplastic resin, but may be a liquid resin material that reacts to form a synthetic resin.
As shown in FIG. 2, during use of the convertible top 2, a tensile stress greater than that of the lower portion 6 b is applied to the upper portion 6 a of the frame member 6 by the tension from the first sheet material 4 and the weight of the window plate 3. Therefore, it is preferable that the contact area between the window plate 3 of the upper portion 6a and the first sheet material 4 is made larger than that of the other portions, so that the tensile stress applied to the upper portion 6a is reduced.
The first sheet material 4 has a sewing allowance 4b for sewing with the second sheet material 5 further outside the portion where the first sheet material is fixed to the frame member 6.
The second sheet material 5 has a similar shape slightly larger than the outer peripheral edge 3a of the window plate 3, and has an opening edge 5a smaller than the sewing allowance 4b of the first sheet material 4, as shown in FIG. As shown in the figure, a sewing allowance 5b is formed by bonding an adhesive layer 10 at the opening edge 5a with its end bent toward the interior of the vehicle interior, and the side surface of the interior of the vehicle interior is also provided with an adhesive layer 11 for the first. The sewing margin 4b of the first sheet material 4 and the sewing margin 5b of the second sheet material 5 are sewn with the sewing thread 7 to sew. A part 8 is formed.
Thereby, it is possible to prevent rainwater from permeating into the passenger compartment from between the first sheet material 4 and the second sheet material 5 in the sewn portion 8 and to sew sufficiently regardless of the material of the sheet materials 4 and 5. The fixing strength can be obtained.
Further, a waterproof seal tape 12 is attached to the sewing allowance 4b of the first sheet material 4 on the vehicle interior side to hide the sewn portion to improve the appearance and to allow rainwater to flow from the sewn portion. It is designed to prevent intrusion into the passenger compartment. As described above, in the present embodiment, the second sheet material 5 is sewn to the first sheet material 4 so that the first sheet material 4 can be fixed to the frame member 6 by an existing method. Since the material of the second sheet member 5 can be freely selected, the degree of freedom in the design of the convertible top 2 can be improved while minimizing the change in the structure and the manufacturing method and suppressing an increase in cost.
As shown in FIG. 4 (b), when the convertible top 2 is used, the outer material 5c facing the outside of the cabin is made of synthetic fiber (eg, acrylic fiber) having high weather resistance. The woven fabric and the lining 5d have a structure in which a cotton woven fabric having a good texture and feel and a synthetic rubber having a waterproof property are laminated as an intermediate material 5e, and are set more flexibly than the window plate 3.
Next, a method and an apparatus for manufacturing a convertible top according to the present invention will be described in the order of steps with reference to the drawings.
5 to 7 show an embodiment of a method and an apparatus for manufacturing a convertible top according to the present invention, showing one step in manufacturing the frame member shown in FIG. 3, and FIG. FIG. 6 is a cross-sectional view showing a process in which a core mold and a cavity mold as molds are clamped by sandwiching a window plate and a first sheet material, and FIG. FIG. 7 is a cross-sectional view showing a step of injecting a synthetic resin serving as a frame member into a cavity in a state, and FIG. FIG.
1 to 4 are denoted by the same reference numerals, and detailed description is omitted.
The apparatus for manufacturing the convertible top 2 according to the present embodiment comprises, on a die plate (not shown), an injection mold 20 made of steel, which can be divided at a division surface. And a liquid synthetic resin is injected and filled with the window plate 3 and the first sheet 4 between the divided surfaces 210 and 220 to form the frame member 6. A cavity 23 is formed.
Thus, the frame member 6 is injection-molded, and the window member 3 and the first sheet material 4 are integrally connected by the frame member 6.
The core mold 21 has a mold surface 211 for forming the cavity 23 on the division surface 210 and a relief recess 212 for preventing contact with the window plate 3 at the center of the surface of the window plate 3.
The dividing surface 210 is provided with positioning pins 24 for positioning the first sheet material 4 at the time of forming the frame member 6, and the positioning pins 24 are moved upward by a compression spring 25 by a compression spring 25. It is urged to the side and fits into a positioning hole 4 e previously drilled in the first sheet material 4 to fix it. Since the positioning pin 24 directly presses the surface of the window plate 3, a material (for example, polyacetal resin) which is softer and more wear-resistant than the window plate 3 is preferable.
The escape recess 212 is provided with a vacuum suction cup 26 for positioning and fixing the window plate 3, and the vacuum suction cup 26 is connected to a vacuum pump (not shown) via a suction pipe 27.
A runner plate 28 is superimposed on the upper surface of the cavity mold 22, and a runner, which is a resin flow path of a synthetic resin supplied from an injection nozzle of an injection molding machine (not shown), is provided on the mating surface with the runner plate 28. The cavity mold 22 has a sprue 30 communicating with the cavity 23 in the middle of the runner 29 and a pinpoint injection gate 30 a facing the cavity 23.
Reference numeral 31 in FIG. 7 denotes a cutter for making a cut in the first sheet material 4 integrated with the frame member 6 by injection molding, trimming the unnecessary portion 400, and shaping.
The mold 20 can have the same structure as a mold for manufacturing an existing convertible top.
Next, a method of manufacturing a convertible top according to this embodiment will be described in the order of steps with reference to FIGS.
First, a positioning hole 4e is formed in the unnecessary portion 400 inside the first sheet material 4 as preparation.
In the first step, as shown in FIG. 5, the first sheet material 4 is fixed to the core mold 21 so that the position of the positioning hole 4e matches the positioning pin 24, and the window plate 3 is placed thereon. The cavity mold 22 is placed on the core mold 21 and the mold 20 is clamped while the outer peripheral edge 3a is arranged at a predetermined position of the cavity 23 and fixed by the vacuum sucker 26.
The adhesive layer 32 as the first fixing means is formed on the outer peripheral edge 3a of the window plate 3 in advance. Further, it is preferable that the window plate 3 is heated and expanded to room temperature or higher until the frame member 6 is formed. This alleviates the internal stress from the frame member 6 that occurs on the window plate 3 due to the cooling and solidification during the frame member 6 forming process, and can prevent the window plate 3 from being deformed or damaged.
In the second step, as shown in FIG. 6, the mold surface 211 of the core mold 21 covered with the first sheet 4 is fixed to the mold surface 221 of the corresponding cavity mold 22 and the cantilever state. A liquid synthetic resin is injected into a cavity 23 formed by the surface of the window plate 3 and the vicinity of the outer peripheral edge 3a to perform injection molding.
That is, injection molding is performed by injecting a liquid thermoplastic synthetic resin heated and melted from the injection gate 30a of the sprue 30 into the cavity 23. However, it is preferable that the position and the injection direction of the injection gate 30a be set so that the injected synthetic resin does not directly hit the window plate 3. Thus, the window plate 3 is not subjected to the pressure of the injected liquid synthetic resin, and the window plate 3 can be prevented from being deformed or cracked.
The liquid synthetic resin in this embodiment is a thermoplastic synthetic resin such as soft PVC, which is softened by heating to be in a flowable state and solidified by cooling.
Thus, the window plate 3 and the first sheet member 4 can be integrated by the frame member 6. This step will be described in detail below.
As shown in FIGS. 5 and 6, when the window plate 3 and the first sheet material 4 are clamped on the divided surfaces 210 and 220 of the core mold 21 and the cavity mold 22, the molding die is formed. A cavity 23 is formed inside 20. The outer peripheral edge 3a of the window plate 3 positioned in a cantilever state between the first sheet material 4 closely contacting the mold surface 211 of the core mold 21 and the mold surface 221 of the cavity mold 22 is formed. It is formed with the neighboring surface, and extends along the longitudinal direction of the window plate 3 and corresponds to a desired shape of the frame member 6 to be formed. In this state, a liquid thermoplastic synthetic resin heated and melted is injected from the injection gate 30a through the sprue 30.
At this time, as shown in FIG. 6, the synthetic resin injected from the injection gate 30 a shown by a solid line slightly outward from the outer peripheral edge 3 a of the window plate 3 is in a cantilevered state protruding into the cavity 23. Does not directly collide with the window plate 3, no bending moment is generated in the window plate 3. Therefore, when the window plate 3 is made of inorganic glass, breakage or cracking can be prevented, and when it is made of synthetic resin, deformation can be prevented.
As shown in FIG. 6, the injected synthetic resin collides with the first sheet material 4 and the mold surface 211 of the core mold 21 located behind the first sheet material 4, and is first filled near the injection gate 30a. Then, it flows in the longitudinal direction of the cavity 23 and fills the whole.
When the synthetic resin is injected and flows, the resin sheet material 4c of the first sheet material 4 is overheated by the heat of the molten synthetic resin and is somewhat softened, and the pressure of the injected synthetic resin in the cavity 23 is increased. It is extended and pressed against the mold surface 211 of the core mold 21 to be formed in a shape along the mold surface 211. Thus, the frame member 6 is formed, and the first sheet material 4 is laminated and integrated on the surface of the frame member 6.
On the other hand, the window plate 3 and the frame member 6 are activated by the heat of the liquid synthetic resin forming the frame member 6 and the injection pressure to activate the adhesive layer 32 as the first fixing means. The surface of the window plate 3 near the outer peripheral edge 3a and the frame member 6 are firmly fixed. In addition, when inorganic glass is used as the window plate 3 and soft or semi-hard PVC resin is used as the frame member, the adhesive as the first fixing means can be an adhesive mainly composed of acryl-modified phenol resin. .
When the resin sheet material 4c of the first sheet material 4 has compatibility with the synthetic resin to be injected, the surface of the resin sheet material 4c is somewhat melted by conduction heat of the injected synthetic resin, and While melting with the synthetic resin forming the member 6, the pressure of the injected synthetic resin acts to form the welded portion 33, thereby firmly fixing the member. In this case, the welding portion 33 serves as a second fixing means. When using soft PVC as a synthetic resin for forming the frame member 6, it is preferable to heat the injected resin to a temperature of about 200 to 220 ° C.
If the same adhesive layer as that of the first fixing means is previously formed as the second fixing means on the first sheet material 4 at the portion where the frame member 6 is formed, this adhesive is used. Are adhered by the synergistic action of the conduction heat and the pressure from the injected synthetic resin, and also in this case, strong adhesion is obtained. The steps up to this step are common to existing manufacturing steps.
In the third step, the intermediate body of the convertible top 2 on which the frame member 6 is formed is taken out of the mold 20 and the unnecessary portion 400 of the first sheet material 4 is trimmed by the cutter 31 having a sharp blade. Shape it. At this time, the inner peripheral edge side of the first sheet material 4 is trimmed along the inner peripheral edge 6d of the formed frame member 6, and the outer peripheral edge side is a sewing margin 4b for sewing with the second sheet material 5 described later. Then, a predetermined width is secured from the outer peripheral edge 6c of the frame member 6 and trimming is performed. If the window plate 3 may be damaged by the cutter 31, manual or electric scissors may be used.
In the fourth step, as shown in FIG. 3, an adhesive layer 10 is previously formed on the vehicle interior side surface near the opening edge of the second sheet material 5, and its end is woven on the vehicle interior side. The adhesive layer 11 is formed on the outer side surface of the sewing allowance 4b of the first sheet material 4 in advance in the turned state.
Then, after the sewing allowance 5b of the second sheet material 5 is superimposed on the sewing allowance 4b of the first sheet material 4 from the outside of the vehicle, the two sheet materials 4, 5 are sewn using the sewing thread 7, and The seal tape 12 is attached to the first sheet material 4 inside the vehicle interior of the sewing portion.
As a result, the first sheet member 4 and the second sheet member 5 are firmly fixed, and it is possible to prevent rainwater from entering between the two sheet members or from the sewn portion into the vehicle interior.
FIG. 8 is a cross-sectional view corresponding to FIG. 3 in the second embodiment of the present invention, and common portions are denoted by the same reference numerals, and detailed description is omitted. As shown in FIG. 8, the opening edge 5a of the second sheet material 5 is extended to the vicinity of the inner peripheral edge 6d of the frame member 6, and the sewing margin 4b of the first sheet material 4 and the second sheet The sewing margin 5b of the material 5 is sewn and bonded, and the inner peripheral side of the sewn portion 8 of the second sheet material 5 is bonded to the vehicle outer surface of the frame member 6.
As a result, the first sheet member 4 and the frame member 6 are covered with respect to the outside of the vehicle by the second sheet member 5, so that the appearance of the convertible top 2 is unified by the second sheet member 5 and the texture is improved. . Further, the first sheet member 4 and the frame member 6 are not exposed to direct sunlight, wind and rain, and a material having low weather resistance can be used for them.
With the above structure, in the vehicle to which the present invention is applied, the structure of the convertible top and the method of manufacturing the convertible top are different from the existing structure in that the sewing margin 4b is provided on the outer peripheral edge of the first sheet material 4. By simply adding a configuration in which the first sheet material 4 and the second sheet material 5 are sewn, the convertible top sheet material can be freely selected, the degree of freedom in design can be improved, and the existing design can be improved. Since the manufacturing method and the process of the structure are common halfway, the existing manufacturing equipment can be used as it is, and the mixed production with the existing structure is possible, so that the manufacturing cost can be reduced.
[Brief description of the drawings]
FIG. 1 is a rear perspective view of a convertible top according to a first embodiment of the present invention.
FIG. 2 is an enlarged view of the vicinity of a window plate in the first embodiment of the present invention.
FIG. 3 is a cross-sectional view of the vicinity of the window plate taken along line AA shown in FIG. 2 in the first embodiment of the present invention.
FIG. 4 is a schematic diagram showing a laminated structure of first and second sheet materials of the present invention.
FIG. 5 is a cross-sectional view showing one step when forming a frame member in the first embodiment of the present invention.
FIG. 6 is a cross-sectional view showing one step when forming a frame member according to the first embodiment of the present invention.
FIG. 7 is a cross-sectional view showing one step when forming a frame member according to the first embodiment of the present invention.
FIG. 8 is a cross-sectional view of the vicinity of a window plate taken along line AA shown in FIG. 2 in a second embodiment of the present invention.
FIG. 9 is a sectional view of a conventional convertible top corresponding to FIG.
[Explanation of symbols]
1 ... Vehicle
2 ... Convertible top
3 Window plate
4 First sheet material
5 Second sheet material
6 Frame member
7 ... sewing thread
8 ... sewing part
11 ... adhesive layer (for bonding the first sheet material and the second sheet material)
12 ... Seal tape
20: Mold
23 ・・・ Cavity
32 ... adhesive layer (first fixing means)
33 ... welded portion (second fixing means)

Claims

A window plate made of a transparent material and having both front and back surfaces and a predetermined outer peripheral surface shape, and a first plate made of a material which has an opening edge substantially the same as or similar to the outer peripheral edge shape of the window plate and is more flexible than the window plate. In order to connect and integrate the sheet material with the window plate and the first sheet material, the window plate is disposed between the vicinity of the outer peripheral edge of the window plate and the vicinity of the opening edge of the first sheet material. A synthetic resin connecting element formed long along the outer peripheral edge, first fixing means for fixing the vicinity of the outer peripheral edge of the window plate and the connecting element, and near the opening edge of the first sheet material And a second fixing means for fixing the connecting element and the connecting element,
The first sheet material is fixed to the connection element so that an outer peripheral edge side thereof has a predetermined width capable of being sewn,
A foldable second sheet material made of a material softer than the window plate and constituting at least a part of the convertible top outer surface is sewn on the first sheet material with sewing thread. Features a convertible top structure.

The connecting element is formed so as to be elongated along the outer peripheral edge of the window plate between the vicinity of the outer peripheral edge of the window plate and the vicinity of the opening edge of the first sheet material, with an irregular cross-sectional shape. hand,
The connecting element is formed of a synthetic resin that is filled and solidified in a compressed state in a cavity of a mold for molding the connecting element, and the cavity is formed near an outer peripheral edge of the window plate. 2. The convertible according to claim 1, wherein the first fixing member is fixed inside the first sheet material, and the second fixing member is fixed to the vicinity of an opening edge of the first sheet material. Top structure.

The structure of the convertible top according to claim 1 or 2, wherein the first sheet material and the second sheet material are sewn after being joined with a waterproof adhesive.

The convertible top according to any one of claims 1 to 3, wherein a seal tape is adhered to a sewn portion between the first sheet material and the second sheet material on the vehicle interior side. Construction.

The structure of the convertible top according to any one of claims 1 to 4, wherein the second sheet material is sewn so as to cover the first sheet material from the outside of the vehicle.

The structure of a convertible top according to any one of claims 1 to 5, wherein the second sheet material is a canvas material on both sides of the second sheet material.

The second sheet material has a surface material made of a synthetic fiber woven fabric facing the outside of the vehicle, a lining made of a natural fiber woven fabric facing the inside of the vehicle, and a waterproof material sandwiched between the surface material and the lining. The structure of a convertible top according to claim 6, comprising an intermediate material made of a material.

A window plate made of a transparent material and having both front and back surfaces and a predetermined outer peripheral surface shape, and a first plate made of a material which has an opening edge substantially the same as or similar to the outer peripheral edge shape of the window plate and is more flexible than the window plate. The sheet material, and the window plate between the vicinity of the outer peripheral edge of the window plate and the vicinity of the opening edge of the first sheet material in order to connect and integrate the window sheet and the first sheet material. A connecting element made of synthetic resin formed along the outer peripheral edge of the first sheet material, first fixing means for fixing the connecting element to the vicinity of the outer peripheral edge of the window plate, and an opening edge of the first sheet material A method of manufacturing a convertible top, comprising: a second fixing means for fixing the vicinity and the connecting element,
Fixing the connecting element to the vicinity of the outer peripheral edge of the window plate by the first fixing means; fixing the connecting element to the first sheet material by the second fixing means;
Shaping the first sheet material so that the outer peripheral edge side of the first sheet material fixed to the vicinity of the outer peripheral edge of the window plate has a predetermined width that can be sewn; Sewing a second foldable sheet material made of a material softer than the window plate and constituting at least a part of the outer surface of the convertible top with a sewing thread. Method for producing a convertible top.

A window plate made of a transparent material and having both front and back surfaces and a predetermined outer peripheral surface shape, and a first plate made of a material which has an opening edge substantially the same as or similar to the outer peripheral edge shape of the window plate and is more flexible than the window plate. A cross-sectional shape between the vicinity of the outer peripheral edge of the window plate and the vicinity of the opening edge of the first sheet material in order to connect and integrate the sheet material with the window sheet and the first sheet material. A synthetic resin connecting element formed elongate along the outer peripheral edge of the window plate in an irregular shape, first fixing means for fixing the connecting element near the outer peripheral edge of the window plate, and the first fixing means; A method of manufacturing a convertible top, comprising: a second fixing means for fixing the vicinity of an opening edge of a sheet material and the connection element,
The connecting element is formed of a synthetic resin that is filled and solidified in a compressed state in a cavity of a mold for molding the connecting element, and at this time, the first fixing unit fixes the window plate. Fixing to the vicinity of the outer periphery and fixing to the first sheet material by the second fixing means;
Cutting the outer peripheral edge of the first sheet material so as to have a predetermined width capable of being sewn; Sewing a foldable second sheet material that constitutes at least a part of the second sheet material with sewing thread.

The method for manufacturing a convertible top according to claim 8 or 9, further comprising a step of joining the first sheet material and the second sheet material with a waterproof adhesive before sewing. .

The convertible top according to any one of claims 8 to 10, further comprising a step of attaching a seal tape to a sewn portion between the first sheet material and the second sheet material on the vehicle interior side. Manufacturing method.

The method for manufacturing a convertible top according to any one of claims 8 to 11, further comprising a step of covering the second sheet material with the first sheet material from outside of the vehicle and sewing. .