The present invention relates to a mounting structure for an EA material (an impact energy absorbing material), and more particularly to a mounting structure for an EA material suitable for use in a trim of an automobile.
For impact energy absorption (Energy Absorption: EA) in the event of a collision on a side (a lateral collision), an EA material made of rigid urethane is mounted to a door trim of an automobile. As a method for mounting the EA material made of rigid urethane to the door trim, Japanese Unexamined Patent Application Publication No. 2001-322507 describes the structure illustrated in FIGS. 7, 8a, and 8b. FIG. 7 is a cross-sectional view illustrating a mounting structure for an EA material described in FIG. 7 of the above publication.
The cap 20 integrally includes a cylindrical portion 21 and a flanged portion 22. The cylindrical portion 21 is provided with a pawl 23 directed inwardly from the leading end of the cylindrical portion 21. A rod 26 projects from a trim 31, and a concavity 27 is formed around the outer circumferential surface of the rod 26. The pawl 23 engages with the concavity 27.
The cylindrical portion 21 is formed with slits 24 extending from the leading end thereof in the direction parallel to the axis center line of the cylindrical portion 21. The cylindrical portion 21 is elastically deformable in the diameter expanding direction thereof.
To mount an EA material 33 to the trim 31, the EA material 33 is aligned with the surface of the trim 31 such that the rod 26 is inserted into a mounting hole 34 of the EA material 33. Then, the cap 20 is fitted and pressed onto the rod 26 to engage the pawl 23 with the concavity 27. Thereby, the flanged portion 22 presses the peripheral region around the mounting hole 34 of the EA material 33.
The cylindrical portion 21 is formed in a taper shape tapered toward the leading end thereof, and thus can be easily inserted into the mounting hole 34. In a state in which the cap 20 is fitted to the rod 26, the outer circumferential surface of the cylindrical portion 21 is in close contact with the inner circumferential surface of the mounting hole 34.
In the above conventional mounting structure for an EA material, the cap 20 and the EA material 33 are separate from each other. The mounting of the EA material to the trim 31, therefore, requires two operation processes, i.e., an operation of applying the EA material to the trim 31, and a subsequent operation of fitting the cap 20 onto the rod 26. As a result, the operations become troublesome.
When a passenger hits the EA material 33 and the EA material 33 is crushed and deformed, the cap 20 resists the crushing deformation, and the EA characteristic is decreased for that.
Since the pawl 23 can move in the concavity 27, the EA material 33 may move in the horizontal and vertical directions in
An object of the present invention is to provide a mounting structure for an EA material capable of remarkably improving the workability of the mounting operation of the EA material to such a member as a trim, and providing a good EA characteristic.
Another object of the present invention is to provide a mounting structure for an EA material capable of securely mounting the EA material to such a member as a trim, and preventing the movement of the EA material and the occurrence of abnormal noise.
A mounting structure for an EA material according to the first aspect is characterized in that, in a structure in which the EA material is mounted to a member, the member includes a rib and the EA material includes a concave slit into which the rib fits, that the EA material integrally includes a clip having a pair of facing pieces disposed to the inner surface of the concave slit to face each other across the concave slit and a bridging piece connecting the facing pieces, and that the pair of facing pieces nip the rib.
In the mounting structure for an EA material according to the first aspect, the clip is integrated with the EA material. Thus, through a single operation process of engaging the clip with the rib of the member while applying the EA material having the rib to the member, the EA material can be mounted to the member.
Since the facing pieces of the clip nip the rib, the EA material does not rattle, and the abnormal noise is not generated.
With pawls of the clip digging into the side surfaces of the rib, the rib is prevented from moving in the direction of escaping from the clip. Accordingly, the EA material is highly securely mounted.
If the clip is provided with surface pieces extending from the respective facing pieces in directions of separating from each other and disposed along the surface of the EA material, the clip can be accurately fitted in a mold for molding the EA material in manufacturing the EA material having the clip. That is, the position of the clip is stabilized by making the surface pieces in contact with the inner surface of the mold.
If the clip is provided with anchor pieces buried in the EA material, the clip can be solidly integrated with the EA material.
If the length in the longitudinal direction of the rib is made shorter than the length in the longitudinal direction of the concave slit, a small positional error, if any, between the EA material and the member such as the trim can be absorbed.
If the member such as the trim is provided with a plurality of ribs which are approximately perpendicular to one another in the longitudinal direction thereof, the EA material can be reliably fastened in two perpendicular directions along the surface of the member.
The clip is preferably made of a metal for its high strength. For the molding to integrate the clip with the EA material, a mold for molding the EA material may be provided with a magnet so that the clip made of a ferromagnetic metal (e.g., iron) is held by the mold by the magnetic force of the magnet.
The rib is preferably made of a synthetic resin.
A mounting structure for an EA material according to the second aspect is characterized in that, in a structure in which the EA material is mounted to a member, a convex locking portion provided on the member is inserted into a plate-like locked portion formed with a hole and integrated with the EA material, through the hole, and that pawls projecting from the rim of the hole engage with the locking portion to thereby mount the EA material to the member.
In the mounting structure for an EA material according to the second aspect, the locked portion is integrated with the EA material. Thus, through a single operation process of engaging the locked portion with the locking portion of the member while applying the EA material having the locking portion to the member, the EA material can be mounted to the member.
The locked portion may be provided on the surface of the EA material. If the EA material is made of a foamed resin such as urethane foam, the locked portion is securely adhered to and integrated with the surface of the EA material.
With pawls of the locked portion digging into the side surface of the locking portion, the locking portion is prevented from moving in the direction of escaping from the locked portion. Accordingly, the EA material is highly securely mounted.
The hole of the locked portion may be a round hole (a circular hole), or may be in a rectangular shape. A cylindrical locking portion is preferably inserted into the round hole. Meanwhile, either one of a circular locking portion and a rib-like locking portion of a flat plate shape may be inserted into the rectangular hole. If the cylindrical locking portion is inserted into the rectangular hole, a small positional error, if any, between the EA material and the member such as the trim can be absorbed.
The locked portion is preferably made of a metal for its high strength. To integrate the locked portion with the EA material, a mold for molding the EA material may be provided with a magnet so that the locked portion made of a ferromagnetic metal (e.g., iron) is held by the mold by the magnetic force of the magnet.
The locking portion is preferably made of a synthetic resin.
In the present invention, the EA material is preferably made of synthetic resin foam (a foamed material) such as rigid urethane foam.
The mounting structure for an EA material is suitable for use in the mounting of a door trim placed along the inner surface of an automobile cabin. However, the mounting structure for an EA material is not limited to this.
a is a cross-sectional view illustrating a mounting structure for an EA material of an embodiment according to the first aspect.
a,
4
b, and 4c are cross-sectional views for explaining a method of manufacturing the EA material having the clip.
a and 8b are explanatory diagrams of the structure shown in
a is a cross-sectional view in an approximately horizontal direction illustrating a mounting structure for an EA material of an embodiment according to the second aspect.
a and 12b are cross-sectional views for explaining a method of manufacturing the EA material having the locked portion.
With reference to the drawings, embodiments will be described.
As illustrated in
The rib 3 is formed by a flat plate provided to stand from the trim 2. The leading end side in the standing direction of the rib 3 may be chamfered into a tapered portion which decreases in width toward the leading end thereof.
The clip 4 is formed by an approximately U-shaped clasp having a pair of facing pieces 4a and 4a and a bridging piece 4b connecting the facing pieces 4a and 4a.
In the present embodiment, the facing pieces 4a and 4a are provided with surface pieces 4c and 4c extending from the leading ends thereof in directions of separating from each other.
Each of the facing pieces 4a and 4a is provided with pawls 5 projecting therefrom. The respective pawls 5 and 5 extend in a tongue shape toward the bridging piece 4b from the leading end side of the facing pieces 4a (the side of the surface pieces 4c). The pawls 5 and 5 are inclined with respect to the plate surfaces of the facing pieces 4a and 4a such that the pawls 5 and 5 approach each other toward the leading ends thereof. The crossing angle of each of the pawls 5 and the corresponding facing piece 4a is preferably approximately 20 to 45°. In a state in which the rib 3 is not engaged with the clip 4, the interval between the leading ends of the pawls 5 and 5 is smaller than the thickness of the rib 3, and the leading ends of the pawls 5 and 5 may be in contact with each other.
In the present embodiment, the facing pieces 4a and 4a are provided with anchor pieces 6 projecting therefrom in directions of separating from each other.
The clip 4 is integrated with the EA material 1 to fit along the inner surface of a concave slit 7 formed in the EA material 1. The facing pieces 4a and 4a are disposed to the side surfaces of the concave slit 7, and the bridging piece 4b is disposed to the bottom surface of the concave slit 7. The surface pieces 4c are disposed along the surface of the EA material 1.
In the present embodiment, ribs 3 and 3A are provided on the EA material 1 to extend in two perpendicular directions. Correspondingly, two concave slits 7 and 7A are formed in the EA material 1.
A multitude (two in the drawing) of the clips 4 are provided in the longer concave slit 7, while a small number (one in the drawing) of the clips 4 are provided in the shorter concave slit 7 (7A).
The EA material 1 having the clips 4 is mounted to the trim 2 by applying the EA material 1 to the trim 2 while inserting the ribs 3 into the concave slits 7. When the EA material 1 is pressed against the trim 2, the ribs 3 and 3A are pressed into the concave slits 7 and 7A, while sliding against the leading ends of the respective pawls 5. Then, the leading ends of the respective pawls 5 dig into the side circumferential surfaces of the ribs 3 and 3A, so that the ribs 3 and 3A are prevented from escaping from the concave slits 7 and 7A. Thereby, the EA material 1 is mounted to the trim 2.
In this way, solely through the single operation process of superimposing the EA material 1 having the clips 4 on the trim 2, the EA material 1 can be mounted to the trim 2. Accordingly, the working efficiency of the mounting operation is remarkably improved. Further, since the ribs 3 and 3A and the concave slits 7 and 7A are provided in the two perpendicular directions, the EA material 1 can be fastened in the two perpendicular directions on the plate surface of the trim 2. Furthermore, since the respective pawls 5 dig into the ribs 3 and 3A, the ribs 3 and 3A are immobile with respect to the clips 4. Thus, the EA material 1 is securely mounted, and the rattling of the EA material 1 and the occurrence of abnormal noise are prevented.
In the present embodiment, the ribs 3 and 3A are shaped into plates of a low height. Thus, when the EA material 1 is crushed and deformed, the ribs 3 and 3A do not act as a resistance. Further, even in the area near the ribs 3 and 3A, the EA material 1 has a sufficient thickness and thus has a good impact absorbing characteristic.
In the mounting structure for the EA material 1, the length in the longitudinal direction of each of the ribs 3 and 3A is shorter than the length in the longitudinal direction of the corresponding one of the concave slits 7 and 7A. Therefore, a small positional error, if any, in the ribs 3 and 3A and the concave slits 7 and 7A can be absorbed.
To manufacture the EA material 1 having the clips 4, a mold including a lower mold 10 and an upper mold 11 is used, as illustrated in
As illustrated in
When the original solution of the resin is foamed, as illustrated in
The above-described embodiment is one example of the present invention. Thus, the present invention may be implemented in other embodiments than the illustrated one. For example, the number of the pawls may be different from the illustrated one. Further, as in the case of a clip 4A shown in
a is a cross-sectional view in an approximately horizontal direction illustrating a mounting structure for an EA material of an embodiment according to the second aspect.
As illustrated in
The locking portion 43 is formed by a cylinder provided to stand from trim 42. The leading end side in the standing direction of the locking portion 43 is formed with a tapered portion 43a which decreases in diameter toward the leading end thereof. Thus, the locking portion 43 can be easily inserted into the locked portion 44.
The locked portion 44 is shaped into a plate of a small thickness and disposed on the surface of the EA material 41. The locked portion 44 is formed with a circular hole 44a. The hole 44a is provided with a plurality of pawls 45 projecting from the inner circumferential rim thereof. In the present embodiment, the pawls 45 are each in a triangular shape and aligned in the circumferential direction of the hole 44a. The respective pawls 45 are inclined to slightly stand toward one side in the axis center direction of the hole 44a. The crossing angle of the plate surfaces of the pawls 45 and the circular disk surface of the locked portion 44 is preferably approximately 30 to 160°.
The EA material 41 is formed with a cavity 46 concentric with the hole 44a. The diameter of the cavity 46 is equal to the diameter of a circle passing through the leading ends of the respective pawls 45. The pawls 45 stand toward the direction of entering into the cavity 46.
In a state in which the locking portion 43 is not inserted in the hole 44a, the diameter of the locking portion 43 is preferably approximately 1.1 to 1.5 times as large as the diameter of the circle passing through the leading ends of the respective pawls 45.
Although only one of the locked portion 44 is shown in
The EA material 41 having the locked portion 44 is mounted to the trim 42 by applying the EA material 41 to the trim 42 while inserting the locking portion 43 into the cavity 46 through the hole 44a. When the EA material 41 is pressed against the trim 42, the locking portion 43 is inserted into the cavity 46 through the hole 44a while sliding against the leading ends of the respective pawls 45. Then, the leading ends of the respective pawls 45 dig into the side circumferential surface of the locking portion 43, and the locking portion 43 becomes immobile with respect to the hole 44a. Thereby, the EA material 41 is mounted to the trim 42.
In this way, solely through the single operation process of superimposing the EA material 41 having the locked portion 44 on the trim 42, the EA material 41 can be mounted to the trim 42. Accordingly, the working efficiency of the mounting operation is remarkably improved. Further, since the respective pawls 45 surrounding the locking portion 43 dig into the locking portion 43, the locking portion 43 is immobile with respect to the locked portion 44. Thus, the EA material 41 is securely mounted, and the rattling of the EA material 41 and the occurrence of abnormal noise are prevented.
As illustrated in
In the mounting structure for the EA material 41, the location and the number of the locking portion 43 and the locked portion 44 are arbitrary, and EA materials of various shapes can be securely and easily mounted to the trim. Further, even if the EA material is soft, the EA material can be securely fastened by increasing the number of the locking portion 43 and the locked portion 44.
To manufacture the EA material 41 having the locked portion 44, a mold including a lower mold 50 and an upper mold 51 is used, as illustrated in
When the original solution of the resin is foamed, the foamed rein adheres to the locked portion 44, and the EA material 41 integrated with the locked portion 44 is molded. Then, the upper mold 51 is removed for the mold removal, and the EA material 41 having the locked portion 44 is molded, as illustrated in
The above-described embodiment is one example of the present invention. Thus, the present invention may be implemented in other embodiments than the illustrated one. For example, as in the case of pawls 45A of a locked portion 44A shown in
Similarly to the above-described locked portion 44, the locked portion 54 including the rectangular hole 54a is integrated with the surface of the EA material (the illustration of the EA material is omitted in
In
The cylindrical locking portion 43 can be inserted at an arbitrary position in the longitudinal direction (the X direction) of the hole 54a. Therefore, even if there is a small error in the relative positional relationship between the locking portion 43 and the locked portion 54, such an error can be absorbed.
Number | Date | Country | Kind |
---|---|---|---|
2004-124433 | Apr 2004 | JP | national |
2004-124434 | Apr 2004 | JP | national |
This is a continuation application of PCT/JP2005/007430 filed on Apr. 19, 2005.
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Number | Date | Country | |
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Number | Date | Country | |
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Parent | PCT/JP2005/007430 | Apr 2005 | US |
Child | 11583899 | US |