Vehicle door opening regulation mechanism and method for manufacturing the lever

Abstract

To improve the durability of a stopper section of a lever of a vehicle door opening regulation mechanism.SOLUTION: A vehicle door opening regulation mechanism 100 is configured to regulate door opening by bringing a metal plate 2 and an end face 5a of a stopper section 5 on the side of a base end in a lever longitudinal direction in a lever 1 which is made of resin m into contact with a case 10. The plate 2 includes a buried section 2a and a protruding section 2b which protrudes to the outside from a tip in the lever longitudinal direction of the stopper section 5. The protruding section 2b is bent along a surface 521 which is opposite the end surface 5a of the stopper section 5 in the lever longitudinal direction, and holds the stopper section 5 from the tip in the level longitudinal direction. A lever manufacturing method for manufacturing the lever 1 includes: forming an intermediate body of the lever 1 by ejecting resin between a metal mold and a surface of a part of the plate 2 which corresponds to the buried section 2a in the intermediate body; and, after forming the intermediate body of the lever 1, bending a part corresponding to the protruding section 2b to produce the lever 1.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a vehicle door opening degree restricting mechanism and a method for manufacturing a lever. [Background technology]

[0002] A vehicle such as an automobile may be provided with a door opening degree regulation mechanism for regulating the door opening degree (fully open position). One example of the door opening degree regulation mechanism is a car door checker disclosed in Patent Document 1.

[0003] The automobile door checker disclosed in Patent Document 1 includes a case fixed to the rear surface of a door sidewall that is connected to the vehicle body via a hinge, a bracket fixed to the vehicle body, and a check lever composed of a metal core plate and a resin outer shell that covers the core plate. The check lever penetrates the door sidewall and the case, with the base end of the check lever rotatably connected to the bracket and the tip end of the check lever located inside the door. The tip end of the check lever is larger than the portion of the check lever that penetrates through the case (the middle portion). The inner end of the tip end of the check lever (the end face on the base end side in the lever's longitudinal direction) abuts against the case via a cushion member, so that the tip end of the check lever functions as a full-open stopper that determines the full-open position of the door (i.e., the door opening angle). The tip of this check lever (full-open stopper) is composed of the tip of the core plate, an anchor pin fitted into a pin hole formed in the tip of the core plate, and a resin bulge that is molded integrally with the outer skin to completely encase the tip of the core plate and the anchor pin, and the opening force when the door is fully open is received by the resin of the step at the inner end of the full-open stopper (the end face of the full-open stopper on the base end side of the lever longitudinal direction). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-190431 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the tip of the check lever (full-open stopper) disclosed in Patent Document 1 has not only a metal core plate but also an anchor pin embedded inside that penetrates this core plate, and since the tip of the check lever (full-open stopper) is molded with a complex structure, residual stress is likely to occur inside the resin, and there is a risk that the desired durability will not be achieved.

[0006] Therefore, the present invention aims to provide a vehicle door opening degree regulating mechanism and a lever manufacturing method that have a structure that can suppress the occurrence of residual stress in the tip portion (stopper portion) of the lever and improve durability. [Means for solving the problem]

[0007] According to one aspect of the present invention, there is provided a vehicle door opening degree limiting mechanism, the vehicle door opening degree limiting mechanism including: a case fixed to a back surface of a door side wall of a door that is attached via a hinge to a door opening formed in a vehicle body, a bracket attached to a portion of the door opening facing the door side wall, and a lever made of a metal plate and a resin covering the plate, the lever being divided into a base end portion pivotably attached to the bracket, an intermediate portion continuous with the base end portion and extending so as to penetrate the door side wall and the case, and a stopper portion extending continuous with the intermediate portion, located inside the door, and having a cross-sectional area larger than that of the intermediate portion, for limiting the opening degree of the door, wherein an end face of the stopper portion on the base end side in the lever longitudinal direction is brought into contact with the case to limit the opening degree of the door. In this vehicle door opening degree regulating mechanism, the plate comprises an embedded portion extending from the inside of the base end portion to the inside of the stopper portion, and a protruding portion that is continuous with the embedded portion and protrudes outward from the tip of the stopper portion in the lever longitudinal direction, and the protruding portion is bent so as to follow the surface of the stopper portion opposite the end face in the lever longitudinal direction, and holds the stopper portion from the tip side in the lever longitudinal direction.

[0008] According to another aspect of the present invention, there is provided a lever manufacturing method for manufacturing the lever of the vehicle door opening degree limiting mechanism, wherein the plate includes an embedded portion extending from an interior of the base end portion to an interior of the stopper portion and a protruding portion continuous with the embedded portion and protruding outward from a tip end of the stopper portion in the lever longitudinal direction, the protruding portion being bent along a surface of the stopper portion opposite the end face in the lever longitudinal direction to hold the stopper portion from the tip end side in the lever longitudinal direction, the lever manufacturing method including: a plate intermediate forming step of forming a plate intermediate that is an intermediate of the plate, the plate intermediate having a portion corresponding to the protruding portion extending linearly and continuous with the embedded portion; a molding step of molding the lever intermediate by injecting resin between a surface of the plate intermediate that corresponds to the embedded portion and a mold; and a bending step of, after the molding step, bending the portion corresponding to the protruding portion along a surface of the lever intermediate on the tip side in the lever longitudinal direction. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a vehicle door opening degree limiting mechanism and a lever manufacturing method that have a structure that can suppress the occurrence of residual stress in the stopper portion of the lever and improve durability. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a partial perspective view of a vehicle including a vehicle door opening degree limiting mechanism according to an embodiment; [Figure 2] FIG. 2 is a perspective view of a vehicle door opening degree limiting mechanism. [Figure 3] FIG. 2 is a perspective view of a vehicle door opening degree limiting mechanism. [Figure 4] FIG. 2 is a side view of the vehicle door opening degree limiting mechanism. [Figure 5] FIG. 2 is a perspective view of a lever of the vehicle door opening degree limiting mechanism. [Figure 6] FIG. 10 is a perspective view of the plate of the lever. [Figure 7]10A to 10C are diagrams illustrating a lever manufacturing method for manufacturing a lever. [Figure 8] 10A to 10C are diagrams illustrating a lever manufacturing method for manufacturing a lever. [Figure 9] 10A to 10C are diagrams illustrating a lever manufacturing method for manufacturing a lever. [Figure 10] 10A to 10C are diagrams illustrating a lever manufacturing method for manufacturing a lever. DETAILED DESCRIPTION OF THE INVENTION

[0011] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a vehicle door opening degree limiting mechanism and a lever manufacturing method according to the present invention will be described with reference to the accompanying drawings.

[0012] Fig. 1 is a partial perspective view of a vehicle including a vehicle door opening degree limiting mechanism 100 according to one embodiment of the present invention. Figs. 2 to 4 are overall views of the vehicle door opening degree limiting mechanism 100, with Figs. 2 and 3 being perspective views and Fig. 4 being a side view. Fig. 1 shows the door in a fully open state, and Figs. 2 to 4 show the door in a fully closed state, with a vehicle body B and door D, described below, removed in Figs. 2 to 4. In the drawings, the direction of arrow F indicates the front in the fore-and-aft direction of the vehicle. Arrows R and L indicate the right and left sides when an occupant looks forward of the vehicle. Arrow U indicates the upper side of the vehicle.

[0013] As shown in FIG. 1, the vehicle door opening degree regulating mechanism 100 is a mechanism that connects the vehicle body B and the door D of the vehicle and regulates the opening degree of the door D (i.e., the door fully open position), and includes a lever 1, a case 10, and a bracket 20.

[0014] The door D to which the vehicle door opening degree limiting mechanism 100 is applied is a hinged door that opens and closes a door opening B1 formed in a vehicle body B of the vehicle. In this embodiment, the door opening B1 is formed on the side of the vehicle body, and the door D is a side door. FIG. 1 shows, as an example, a state in which the vehicle door opening degree limiting mechanism 100 is applied to the right side door (door D) when an occupant in the vehicle cabin looks forward in the front-to-rear direction of the vehicle.

[0015] The door D has a door side wall D1 attached to a door opening B1 of a vehicle body B via a hinge H. In this embodiment, the door side wall D1 is a front wall located at the front of the door D in the vehicle longitudinal direction when the door is closed, and extends in the vehicle vertical direction. Therefore, a portion B11 of the door opening B1 facing the door side wall D1 is a front edge portion of the door opening B1 in the vehicle longitudinal direction when the door is closed. In this embodiment, the vehicle door opening degree limiting mechanism 100 is provided to connect the front wall (door side wall D1) of the door D and the front edge portion of the door opening B1 in the vehicle longitudinal direction (portion B11 facing the door side wall D1 when the door is closed).

[0016] In this embodiment, two hinges H spaced apart from each other in the vehicle vertical direction are attached to a door side wall D1 of the door D, and the vehicle door opening degree limiting mechanism 100 is located between the two hinges H in the vehicle vertical direction. Each hinge H has a door rotation shaft H1 extending in the vertical direction.

[0017] The lever 1 is a main component that determines the opening degree of the door D, and is made of a metal plate 2 and a resin m that covers the plate 2. The plate 2 is formed using a metal plate material having a predetermined plate thickness t. The resin m may be made of, for example, a predetermined fiber-reinforced resin. However, a resin m that does not contain fibers may also be used.

[0018] The lever 1 is formed as a part having a predetermined length that is long in one direction as a whole. The end of the lever 1 on the vehicle body side in the lever longitudinal direction (in other words, the end on the base end side in the lever longitudinal direction, or more specifically, the base end) is attached to the vehicle body B via a bracket 20, and the end of the lever 1 on the door side in the lever longitudinal direction (in other words, the end on the tip end side in the lever longitudinal direction, or more specifically, the tip end) is located inside the door D.

[0019] 1 to 4, the lever 1 is divided into a base end portion 3 rotatably attached to the bracket 20, an intermediate portion 4 that is continuous with the base end portion 3 and extends so as to penetrate the door side wall D1 and the case 10, and a stopper portion 5 that is continuous with the intermediate portion 4, is located inside the door D, has a cross-sectional area larger than that of the intermediate portion 4, and determines the opening degree of the door D. The detailed structure of the lever 1 will be described later.

[0020] The case 10 is a component fixed to the rear surface of the door sidewall D1. The case 10 is generally formed in the shape of a hollow rectangular box. Although not particularly limited, the case 10 comprises a box-shaped case body 11 with one end open and a case cover 12 attached to the case body 11 to cover the opening. The bottom of the case body 11 and the case cover 12 are generally formed in a rectangular shape that is long in the vertical direction of the vehicle. The case 10 is fixed to the rear surface of the door sidewall D1 with the long side of the bottom of the case body 11 extending in the vertical direction of the vehicle. Specifically, two stud bolts 13, 13 spaced apart from each other in the vertical direction of the vehicle are provided on the bottom of the case body 11. Each stud bolt 13 penetrates the door sidewall D1 of the door D from the rear side, and a nut 14 is screwed onto the stud bolt 13, thereby fixing the case 10 to the rear surface of the door sidewall D1. 1, a sidewall through-hole D1a is formed in the door sidewall D1 between the two stud bolts 13, 13, and the middle portion 4 of the lever 1 is inserted through the sidewall through-hole D1a. The sidewall through-hole D1a is formed in a rectangular shape and has an opening area larger than the cross-sectional area of ​​the middle portion 4 of the lever 1.

[0021] 2 to 4, a bottom through-hole 11a is opened in the bottom of the case body 11 of the case 10 (see FIGS. 2 and 4), and a cover through-hole 12a is opened in the case cover 12 (see FIG. 3). The bottom through-hole 11a and the cover through-hole 12a are formed to match the shape and size of the side wall through-hole D1a, and the middle portion 4 of the lever 1 is configured to penetrate the case 10 through the side wall through-hole D1a, the bottom through-hole 11a, and the cover through-hole 12a.

[0022] A pair of shoes 15a, 15b are provided inside the case 10. One shoe 15a is urged from above by a biasing member (e.g., a spring) not shown toward the middle portion 4 of the lever 1, and the other shoe 15b is urged from below by a biasing member (e.g., a spring) not shown toward the middle portion 4 of the lever 1. When the door D is opened or closed, the case 10 moves along the middle portion 4 of the lever 1. At this time, the pair of shoes 15a, 15b urged by the biasing member can slide along the middle portion 4 while sandwiching the middle portion 4 of the lever 1 from above and below.

[0023] The bracket 20 is a member attached to a portion B11 facing the door side wall D1 in the door opening B1 of the vehicle body B. In this embodiment, the bracket 20 is attached to a front edge portion (B11) of the door opening B1 in the vehicle front-rear direction.

[0024] The bracket 20 is made up of a bracket main body 21 and a lever pivot shaft portion 22. The bracket main body 21 is formed with a bolt insertion hole 21a and a shaft fitting hole 21b (see FIG. 4). A bracket fixing bolt 23 for fixing the bracket 20 to the door opening B1 is inserted into the bolt insertion hole 21a. The lever pivot shaft portion 22 extends parallel to the extension direction of the door pivot shaft portion H1 of the hinge H (here, the vertical direction of the vehicle), and is attached to the bracket main body 21 by fitting into the shaft fitting hole 21b of the bracket main body 21.

[0025] The vehicle door opening degree restricting mechanism 100 is configured to restrict the opening degree of the door D by abutting an end face 5a of the stopper portion 5 of the lever 1 on the base end side in the lever longitudinal direction (i.e., on the base end portion 3 side in the lever longitudinal direction) against the case 10. In other words, the movement end of the case 10 in the door opening direction along the lever 1 (middle portion 4) is restricted by the stopper portion 5. An opening force (inertial force of the door D in the door opening direction) when the door is fully opened is received by the end face 5a of the stopper portion 5 on the base end side in the lever longitudinal direction, and an impact force (pressing force) can act on the end face 5a of the stopper portion 5 when the door is fully opened.

[0026] Specifically, in this embodiment, the end face 5a on the base end side of the lever longitudinal direction of the stopper portion 5 directly abuts against the area surrounding the cover through hole 12a formed in the case cover 12 of the case 10 (the end face on the opposite side of the door side wall D1 in the case 10), thereby determining the opening degree (fully open position) of the door D.

[0027] Next, the detailed structure of the lever 1 will be described with reference to FIGS.

[0028] Fig. 5 is a perspective view of lever 1, and Fig. 6 is a perspective view of plate 2 of lever 1. Lever 1 shown in Fig. 5 is also an example of a lever manufactured by a lever manufacturing method described below. Fig. 6 shows the lever 1 shown in Fig. 5 after resin m has been removed, i.e., only plate 2 remains.

[0029] 2 to 5, the lever 1 is divided into the base end portion 3, the intermediate portion 4, and the stopper portion 5 in the longitudinal direction of the lever, as described above. The base end portion 3 is the portion that constitutes the end portion of the lever 1 on the vehicle body side (bracket 20 side) in the longitudinal direction of the lever, the stopper portion 5 is the portion that constitutes the end portion of the lever 1 on the door side in the longitudinal direction of the lever (in other words, the tip portion), and the intermediate portion 4 is the portion that connects the base end portion 3 and the stopper portion 5.

[0030] A fitting hole 3a is formed in the base end 3, and a lever rotation shaft 22 of the bracket 20 fits into the fitting hole 3a. An end of the plate 2 is located inside the base end 3, and the lever rotation shaft 22 penetrates the end of the plate 2. The base end 3 is rotatably attached to the bracket 20 via the lever rotation shaft 22.

[0031] The intermediate portion 4 has a rectangular cross section and extends from the base end portion 3 to the stopper portion 5. The maximum cross-sectional area of ​​the intermediate portion 4 is set smaller than the opening areas of the side wall through-hole D1a, the bottom through-hole 11a, and the cover through-hole 12a, so that the intermediate portion 4 can penetrate the door side wall D1 and the case 10.

[0032] In this embodiment, a plurality of recesses (here, a first recess 4a, a second recess 4b, and a third recess 4c) are formed on each of the upper and lower surfaces of the intermediate portion 4. Each recess (4a, 4b, 4c) is an element that applies resistance to the door D via each shoe (15a, 15b) to hold the door D at a predetermined opening position between the fully closed position and the fully open position. The first recess 4a, the second recess 4b, and the third recess 4c are spaced apart from each other in the longitudinal direction of the lever. The portion of the intermediate portion 4 on the base end 3 side has a cross-sectional area approximately equal to that of the base end 3 and is formed thinner in the vertical direction than the remaining portion of the intermediate portion 4. Furthermore, most of the intermediate portion 4 having each recess (4a, 4b, 4c) is formed wider in the vertical direction than the portion of the intermediate portion 4 near the base end 3. In other words, in this embodiment, most of the intermediate portion 4 has a rectangular cross section with its longer side extending in the vertical direction of the vehicle.

[0033] When the door D is rotated in the door-opening direction from the fully closed position, the upper shoe 15a slides along the upper surface of the intermediate section 4, and the lower shoe 15b slides along the lower surface of the intermediate section 4. When the tips of the shoes 15a and 15b enter the first recess 4a, further rotation of the door D in the opening direction is stopped, and the door D is held at a first opening position (central opening position) that is approximately center between the fully closed position and the fully open position. When an opening force exceeding the holding force of the first recess 4a is applied to the door D at this first opening position, the tips of the shoes 15a and 15b climb over the slope of the first recess 4a and slide along the surface of the intermediate section 4 toward the second recess 4b. When the tips of the shoes 15a and 15b then enter the second recess 4b, the door D is held at a second opening position that is between the first opening position and the fully open position. When an opening force exceeding the holding force of the second recess 4b is applied to the door D at this second opening position, the tip of each shoe 15a, 15b overcomes the slope of the second recess 4b and slides along the surface of the intermediate portion 4 toward the third recess 4c. After that, when the tip of each shoe 15a, 15b enters the third recess 4c, the door D is held at the third opening position, which is between the second opening position and the fully open position and is located near the fully open position. When an opening force exceeding the holding force of the third recess 4c is applied to the door D at this third opening position, the tip of each shoe 15a, 15b overcomes the slope of the third recess 4c and slides along the surface of the intermediate portion 4 toward the stopper portion 5.

[0034] The stopper portion 5 constitutes the end portion (tip portion) on the tip side in the longitudinal direction of the lever 1. As described above, the stopper portion 5 is located inside the door D, has a cross-sectional area larger than the cross-sectional area of ​​the middle portion 4 of the lever 1, and is a portion that determines the opening degree of the door D.

[0035] In this embodiment, the stopper portion 5 comprises an enlarged portion 51 that is continuous with the door D side end of the intermediate portion 4, and a stopper tip portion 52 that is continuous with the enlarged portion 51. The enlarged portion 51 constitutes the portion of the stopper portion 5 that is on the base end side in the lever longitudinal direction. The enlarged portion 51 has an end face 5a that abuts against the case 10. The stopper tip portion 52 constitutes the portion of the stopper portion 5 that is on the tip side in the lever longitudinal direction. Although not particularly limited, the enlarged portion 51 is formed, for example, in the shape of a quadrangular prism. The stopper tip portion 52 is formed, for example, in the shape of a tapered quadrangular pyramid.

[0036] In this embodiment, the portion of the stopper portion 5 on the base end side in the longitudinal direction of the lever is formed wider in the plate thickness direction (in other words, in the normal direction to the upper or lower surface of the plate 2) than the intermediate portion 4. In other words, the expanded portion 51 of the stopper portion 5 is formed wider than the intermediate portion 4, and has a portion that protrudes outward beyond the surface of the intermediate portion 4 in the plate thickness direction.

[0037] In this embodiment, the plate thickness direction coincides with the vehicle up-down direction. That is, in this embodiment, the expanded portion 51, which has an end face 5a on the base end side in the lever longitudinal direction of the stopper portion 5 that abuts against the case 10 and is the portion of the stopper portion 5 on the base end side in the lever longitudinal direction, is formed to be wider than the intermediate portion 4 in the plate thickness direction (vehicle up-down direction). Here, the expanded portion 51 has a portion that protrudes above the upper surface of the intermediate portion 4 and a portion that protrudes below the lower surface of the intermediate portion 4 in the plate thickness direction.

[0038] 2 to 5, in this embodiment, the expanded portion 51 (the portion of the stopper portion 5 on the base end side in the lever longitudinal direction) is also formed slightly wider than the intermediate portion 4 in the plate width direction, which is perpendicular to the plate thickness direction. The expanded portion 51 has a portion that protrudes slightly outward from one side surface (the right side surface or the left side surface) of the intermediate portion 4 in the plate width direction, and a portion that protrudes slightly outward from the other side surface (the left side surface or the right side surface) of the intermediate portion 4 in the plate width direction. The amount of protrusion of the expanded portion 51 from the intermediate portion 4 in the plate width direction is significantly smaller than the amount of protrusion of the expanded portion 51 from the intermediate portion 4 in the plate thickness direction, and the expanded portion 51 has an outer shape that is significantly wider in the plate thickness direction than the intermediate portion 4.

[0039] Specifically, the end face 5a of the stopper portion 5 on the base end side in the lever longitudinal direction, which abuts against the case 10, is the end face of the expanded portion 51 on the intermediate portion 4 side (the base end portion 3 side) in the lever longitudinal direction, and is formed as a rectangular annular flat surface extending in the vehicle up-down direction. The areas of the upper and lower portions of the rectangular annular end face 5a of the expanded portion 51 are significantly larger than the areas of the portions of the end face 5a that protrude outward from the side faces of the intermediate portion 4 in the plate width direction. Therefore, most of the opening force (the inertial force of the door D in the door opening direction) when the door is fully opened is received by the upper and lower portions of the end face 5a on the base end side in the lever longitudinal direction of the stopper portion 5 (the rectangular annular end face 5a of the expanded portion 51), and a large impact force acts on these portions.

[0040] As described above, the stopper tip portion 52 of the stopper portion 5 is formed in a quadrangular pyramid shape and includes a tip surface 521a, an upper inclined surface 521b, a lower inclined surface 521c, a right inclined surface 521d, and a left inclined surface 521e. These surfaces (521a, 521b, 521c, 521d, 521e) form the surface 521 opposite the end surface 5a in the lever longitudinal direction of the stopper portion 5 (stopper tip portion 52). The tip surface 521a extends parallel to the end surface 5a in the vehicle vertical direction. The upper inclined surface 521b extends between the upper surface of the enlarged portion 51 and the tip surface 521a, and is inclined toward the center of the stopper portion 5 in the plate thickness direction (vertical width direction) as it approaches the tip surface 521a. The lower inclined surface 521c extends between the lower surface of the expanded portion 51 and the tip surface 521a, and is inclined so as to approach the center of the stopper portion 5 in the plate thickness direction as it approaches the tip surface 521a. The right inclined surface 521d extends between the right side surface of the expanded portion 51 and the tip surface 521a, and is inclined so as to approach the center of the stopper portion 5 in the plate width direction as it approaches the tip surface 521a. The left inclined surface 521e extends between the left side surface of the expanded portion 51 and the tip surface 521a, and is inclined so as to approach the center of the stopper portion 5 in the plate width direction as it approaches the tip surface 521a.

[0041] Next, the plate 2 of the lever 1 will be described in detail.

[0042] 6, the plate 2 is made of a metal plate having a predetermined thickness t and includes an embedded portion 2a and a protruding portion 2b. Most of the plate 2, except for the protruding portion 2b, is covered with a resin m.

[0043] The embedded portion 2a of the plate 2 extends from inside the base end 3 of the lever 1 to inside the stopper portion 5 of the lever 1. The embedded portion 2a is formed in a roughly strip shape and extends linearly in one direction. The portion of the embedded portion 2a on the bracket 20 side has a flat surface. The lever rotation shaft portion 22 of the bracket 20 is inserted into the portion of the embedded portion 2a that is embedded inside the base end 3 of the lever 1.

[0044] Protruding portion 2b of plate 2 is continuous with embedded portion 2a and protrudes outward from the tip of stopper portion 5 in the lever longitudinal direction. Protruding portion 2b is bent to follow surface 521 opposite end face 5a of stopper portion 5 in the lever longitudinal direction, and holds stopper portion 5 from the tip side in the lever longitudinal direction. In other words, protruding portion 2b abuts surface 521 and holds stopper portion 5 from the side opposite end face 5a.

[0045] In this embodiment, the protrusion 2b is composed of a first protrusion 2b1 and a second protrusion 2b2 that are bent in opposite directions to each other. In this embodiment, the first protrusion 2b1 and the second protrusion 2b2 are bent in opposite directions to each other in the plate thickness direction. In this embodiment, the plate thickness direction coincides with the vehicle vertical direction. Therefore, the first protrusion 2b1 and the second protrusion 2b2 are bent in opposite directions to each other in the vehicle vertical direction. In other words, the first protrusion 2b1 is bent upward at a portion that protrudes from the tip surface 521a of the stopper portion 5, and the second protrusion 2b2 is bent upward at a portion that protrudes from the tip surface 521a of the stopper portion 5.

[0046] In this embodiment, the embedded portion 2a branches into two before the protruding portion 2b. Specifically, the embedded portion 2a has a first branched piece 2a1 and a second branched piece 2a2 that are spaced apart in the plate width direction before the protruding portion 2b. The first branched piece 2a1 is continuous with the first protruding piece 2b1, and the second branched piece 2a2 is continuous with the second protruding piece 2b2. The tip of the first branched piece 2a1 and the tip of the second branched piece 2a2 each extend to a position corresponding to the tip surface 521a of the stopper portion 5.

[0047] In this embodiment, the protruding portion 2b is bent at an acute angle so as to be folded back toward the base end portion 3 of the lever 1. In other words, the inner angle formed between the folded back portion of the protruding portion 2b and the embedded portion 2a is set to an angle smaller than 90°.

[0048] Specifically, the first protruding piece 2b1 of the protruding portion 2b is bent upward in the plate thickness direction so as to run along an upper inclined surface 521b of the surface 521 opposite the end surface 5a of the stopper portion 5 in the lever longitudinal direction and to abut against the upper inclined surface 521b. The second protruding piece 2b2 of the protruding portion 2b is bent downward in the plate thickness direction so as to run along a lower inclined surface 521c of the surface 521 opposite the end surface 5a of the stopper portion 5 in the lever longitudinal direction and to abut against the lower inclined surface 521c.

[0049] More specifically, when the area of ​​end face 5a of stopper portion 5 is projected onto surface 521 opposite end face 5a, and the area of ​​surface 521 corresponding to end face 5a is defined as the end face projection area, protrusion 2b extends from tip surface 521a of stopper portion 5 to a portion including the end face projection area. Specifically, first protrusion 2b1 extends along upper inclined surface 521b to a position adjacent to the upper surface of expanded portion 51 on upper inclined surface 521b. Second protrusion 2b2 extends along lower inclined surface 521c to a position adjacent to the lower surface of expanded portion 51 on lower inclined surface 521c. First protrusion 2b1 extends along upper inclined surface 521b to a projection area corresponding to the upper portion of rectangular annular end face 5a. Second protrusion 2b2 extends along lower inclined surface 521c to a projection area corresponding to the lower portion of rectangular annular end face 5a.

[0050] Next, a method for manufacturing lever 1 will be described with reference to FIGS. 7 to 9. FIG.

[0051] Figures 7 to 10 are diagrams for explaining the lever manufacturing method for manufacturing lever 1. Specifically, Figure 7 is a diagram for explaining the plate intermediate forming process described later (a perspective view of plate intermediate 2'), Figures 8 and 9 are diagrams for explaining the molding process (insert molding process) described later, and Figure 10 is a diagram for explaining the bending process described later.

[0052] The lever manufacturing method includes a plate intermediate forming step, a molding step, and a bending step.

[0053] FIG. 7 shows a perspective view of a plate intermediate 2' formed by the plate intermediate forming step. The plate intermediate forming step is a step of forming the plate intermediate 2'. The plate intermediate 2' is an intermediate of the plate 2 and comprises a portion 2a' corresponding to the embedded portion 2a of the plate 2 (hereinafter referred to as the embedded portion corresponding portion 2a') and a portion 2b' corresponding to the protruding portion 2b of the plate 2 (hereinafter referred to as the protruding portion corresponding portion 2b'). The embedded portion corresponding portion 2a' has the same shape and dimensions as the embedded portion 2a. Unlike the protruding portion 2b, which is bent, the protruding portion corresponding portion 2b' extends linearly, continuing from the embedded portion corresponding portion 2a'. The protruding portion corresponding portion 2b' is formed with the same shape and dimensions as the protruding portion 2b, except for the fact that it extends linearly. In other words, the plate intermediate 2' has the same shape as the plate 2, except for the fact that the protruding portion corresponding portion 2b' extends linearly. Therefore, the plate 2 can be formed by bending the portions 2b' corresponding to the protruding portions of the plate intermediate 2' in the same manner as the protruding portions 2b of the plate 2.

[0054] 8 and 9 show an example of a molding process. The molding process is a process in which a plate intermediate 2' and a resin m are integrally molded by insert molding. In the molding process, first, as shown in FIG. 8, the embedded portion-equivalent portion 2a' of the plate intermediate 2' is positioned within the cavity C of the mold M. In this state, the protruding portion-equivalent portion 2b' of the plate intermediate 2' is located outside the cavity C. Next, as shown in FIG. 9, the molding process molds a lever intermediate 1', which is an intermediate of the lever 1, by injecting resin m between the surface of the embedded portion-equivalent portion 2a' of the plate intermediate 2' and the mold M (i.e., by injecting resin into the cavity C). The lever intermediate 1' has the same shape as the lever 1, except that the protruding portion-equivalent portion 2b' of the plate intermediate 2' extends linearly. The mold splitting position and the injection gate for directing the resin into the cavity C can be set at appropriate positions and directions. 8 and 9, the mold parting position and the injection gate are not shown.

[0055] After the injection of the resin into the cavity C is completed, the resin m of the lever intermediate body 1' is gradually cooled and begins to harden. As the resin m hardens, the portion of the resin m shrinks slightly. Then, as shown in FIG. 10, the lever intermediate body 1' is removed from the mold M. The lever intermediate body 1' may be removed from the mold M after the shrinkage stops (after hardening is complete), or may be removed from the mold M while it is shrinking (before hardening is complete). In this lever intermediate body 1', the plate intermediate body 2' is not completely embedded in the resin m, and a protrusion-equivalent portion 2b', which is part of the plate intermediate body 2', protrudes outward from the tip of the portion corresponding to the stopper portion 5 (hereinafter referred to as the stopper portion-equivalent portion 5') in the longitudinal direction of the lever.

[0056] Generally, when the resin of an injection-molded product hardens, residual stress can occur within the resin. In particular, in the case of insert molding, residual stress is likely to occur due to the difference in thermal expansion coefficient (in other words, shrinkage rate) between the resin and the metal plate embedded within it. Furthermore, this residual stress can reduce durability. Therefore, high durability is required for the stopper portion 5 of the lever 1, which can be subjected to an impact force when the door is fully opened.

[0057] Regarding this durability, in the lever manufacturing method according to this embodiment, in order to effectively suppress the generation of residual stress inside the resin m in the stopper portion-corresponding portion 5' during the molding process, a protrusion-corresponding portion 2b', which is a part of the plate intermediate 2', protrudes outward from the tip of the stopper portion-corresponding portion 5' in the lever longitudinal direction. That is, a part of the plate intermediate 2' (the protrusion-corresponding portion 2b') is exposed to the outside from the tip of the stopper portion-corresponding portion 5' in the lever longitudinal direction, and the resin m around the base end of the protrusion-corresponding portion 2b' is open. As a result, in the part of the stopper portion-corresponding portion 5' of the lever intermediate 1' on the tip side in the lever longitudinal direction, shrinkage of the resin m is effectively promoted, and the generation of residual stress is effectively suppressed. Furthermore, unlike conventional anchor pins that can prevent shrinkage of the resin m, the stopper portion-corresponding portion 5' is not embedded inside; instead, only a flat embedded portion-corresponding portion 2a' that is continuous with the protrusion-corresponding portion 2b' is embedded inside. As a result, the occurrence of residual stress inside the resin m of the stopper portion equivalent portion 5' is more effectively suppressed.

[0058] Next, as shown in FIG. 10, the lever intermediate 1' removed from the mold M is subjected to a bending process. The bending process is a process performed after the molding process, in which the protrusion-equivalent portion 2b' is bent so as to conform to the surface of the lever intermediate 1' at the tip end in the longitudinal direction of the lever. Specifically, the bending process is performed on the lever intermediate 1' after the contraction of the resin m has stopped and the molding process has been completed. Specifically, in the bending process, the protrusion-equivalent portion 2b' is bent up and down so as to conform to the surface of the stopper-equivalent portion 5' at the tip end in the longitudinal direction of the lever. This completes the manufacture of the lever 1 shown in FIG. 5.

[0059] In the vehicle door opening degree limiting mechanism 100 according to this embodiment, the plate 2 of the lever 1 includes an embedded portion 2a extending from the inside of the base end 3 of the lever 1 to the inside of the stopper portion 5, and a protruding portion 2b that is continuous with the embedded portion 2a and protrudes outward from the tip of the stopper portion 5 in the longitudinal direction of the lever. As a result, during the manufacturing process (molding process) of the lever 1, shrinkage of the resin m is effectively promoted in the portion of the stopper portion 5 (the portion corresponding to the stopper portion 5') on the tip side in the longitudinal direction of the lever, and the generation of residual stress is effectively suppressed. Furthermore, because the interior of the stopper portion 5 (the portion corresponding to the stopper portion 5') has a simple structure, the generation of residual stress within the resin m of the stopper portion 5 is more effectively suppressed. As a result, a decrease in durability due to residual stress is suppressed, and durability is improved. Furthermore, the majority of the interior of the stopper portion 5, which receives the impact force when the door is fully opened, is occupied by the resin m, which is likely to have high toughness. That is, since a resin-rich portion is provided between the end face 5a of the stopper portion 5 and the protruding portion 2b of the plate 2, the impact force is effectively absorbed and alleviated by this resin-rich portion.

[0060] The protrusion 2b of the plate 2 is bent to follow the surface of the stopper portion 5 opposite the end surface 5a in the lever longitudinal direction, and holds the stopper portion 5 from the tip side in the lever longitudinal direction. As a result, the vehicle door opening degree limiting mechanism 100 can effectively absorb the impact force that may act on the end surface 5a of the stopper portion 5 when the door is fully opened, not only by the resin m of the stopper portion 5 but also by the protrusion 2b of the metal plate 2 from the side opposite to the input direction of the impact force. As a result, deformation of the stopper portion 5 when the door is fully opened is suppressed, and durability is effectively improved. Furthermore, even if the resin alone cannot ensure support force against the impact force, the protrusion 2b can ensure the necessary support force while suppressing the generation of residual stress.

[0061] According to the lever manufacturing method of this embodiment, in the molding process, the protrusion-equivalent portion 2b', which is a part of the plate intermediate 2', protrudes outward from the tip of the stopper-equivalent portion 5' in the lever longitudinal direction. This effectively promotes shrinkage of the resin m inside the stopper-equivalent portion 5' of the lever intermediate 1', effectively suppressing the generation of residual stress. Furthermore, after the molding process of the lever intermediate 1', the protrusion-equivalent portion 2b' is bent to fit along the surface of the tip side of the lever longitudinal direction of the lever intermediate 1'. Therefore, even if the resin m inside the stopper-equivalent portion 5' of the lever intermediate 1' shrinks during molding, the protrusion-equivalent portion 2b' is bent to abut against the shape of the stopper-equivalent portion 5' after shrinkage. As a result, the generation of a gap between the protrusion 2b and the stopper portion 5 is suppressed, effectively suppressing the generation of cracks or fractures in the resin due to the gap.

[0062] As described above, the vehicle door opening degree limiting mechanism 100 and lever manufacturing method according to this embodiment can provide a vehicle door opening degree limiting mechanism 100 and lever manufacturing method having a structure that can suppress the occurrence of residual stress in the stopper portion 5 of the lever 1 and improve durability.

[0063] In this embodiment, the protrusion 2b is made up of a first protrusion 2b1 and a second protrusion 2b2 that are bent in opposite directions to each other. As a result, the impact force acting on the stopper portion 5 is evenly received by the two protrusions (2b1, 2b2), thereby suppressing the occurrence of stress concentration due to an unbalanced load.

[0064] In this embodiment, the portion of the stopper portion 5 on the base end side in the lever longitudinal direction is formed wider in the plate thickness direction than the intermediate portion 4, and the first protruding piece 2b1 and the second protruding piece 2b2 are bent in opposite directions in the plate thickness direction. This makes it easier to manufacture the plate 2, considering that the plate intermediate body 2' is more easily bent in the plate thickness direction than in the plate width direction.

[0065] In this embodiment, the plate thickness direction coincides with the vehicle vertical direction, and therefore a suitable structure is provided when the stopper portion 5 is formed to be wide in the vehicle vertical direction.

[0066] In this embodiment, the embedded portion 2a is branched into two just before the protruding portion 2b, so that the resin m is also filled into the portion between the branched embedded portion 2a inside the stopper portion 5, improving the peel strength between the resin m inside the stopper portion 5 and the embedded portion 2a, and also improving toughness.

[0067] In this embodiment, the protruding portion 2b is bent at an acute angle so as to be folded back toward the base end portion 3 of the lever 1. This can improve the bearing force against the impact force.

[0068] The protrusion 2b may be a single protrusion rather than being branched into the first protrusion 2b1 and the second protrusion 2b2. The bending direction of the protrusion 2b is not limited to the plate thickness direction, but may be the plate width direction. The enlarged portion 51 of the stopper 5 may be formed wide in the vehicle width direction when the door is closed, not limited to being formed wide in the vehicle vertical direction. In this case, the plate 2 may be embedded in the resin m with the plate width direction parallel to the vehicle vertical direction. In this embodiment, the end face 5a of the stopper 5 on the base end side of the lever longitudinal direction directly abuts against the case 10, but this is not limited thereto. For example, a rectangular, annular cushioning material may be attached to the end face 5a of the stopper 5, and the end face 5a of the stopper 5 may abut against the case 10 via the cushioning material.

[0069] Although the embodiments and modifications of the present invention have been described above, the present invention is not limited to the above-described embodiments and modifications, and further modifications and changes are possible based on the technical concept of the present invention. [Explanation of symbols]

[0070] 1...lever, 1'... lever intermediate, 2...plate, 2a... Buried part, 2b...protrusion, 2b1...first protruding piece, 2b2...second protruding piece, 2'...plate intermediate, 2a'... Part corresponding to the buried part (part corresponding to the buried part), 2b'...protruding part (part corresponding to the protruding part), 3...Proximal end, 4...middle part, 5...Stopper part, 5a...end surface, 521...the surface opposite to the end surface of the stopper portion in the lever longitudinal direction, 10…cases, 20...bracket, 100...Vehicle door opening degree regulation mechanism, B...car body, B1: Door opening, B11...Front edge portion (portion facing the door side wall at the door opening), D1: Door side wall, D...door, H...hinge, m...resin, M...mold

Claims

1. a case fixed to a rear surface of a door side wall of a door having a door side wall attached via a hinge to a door opening formed in a vehicle body; a bracket attached to a portion of the door opening facing the door side wall; a lever made of a metal plate and a resin covering the plate, the lever being divided into a base end portion rotatably attached to the bracket, an intermediate portion continuous with the base end portion and extending so as to penetrate the door side wall and the case, and a stopper portion continuous with the intermediate portion, positioned inside the door, having a cross-sectional area larger than that of the intermediate portion, and determining the opening degree of the door; a stopper portion having a base end surface in a lever longitudinal direction abutting against the case, thereby defining an opening degree of the door; the plate includes an embedded portion extending from the inside of the base end portion to the inside of the stopper portion, and a protruding portion that is continuous with the embedded portion and protrudes outward from the tip of the stopper portion in the lever longitudinal direction, The vehicle door opening degree limiting mechanism is characterized in that the protrusion is bent so as to follow the surface of the stopper portion opposite the end face in the lever longitudinal direction, and holds the stopper portion from the tip side in the lever longitudinal direction.

2. 2. The vehicle door opening degree restricting mechanism according to claim 1, wherein the protrusion comprises a first protruding piece and a second protruding piece that are bent in opposite directions.

3. a portion of the stopper portion on the base end side in the lever longitudinal direction is formed wider than the intermediate portion in the plate thickness direction, The vehicle door opening degree restricting mechanism according to claim 2 , wherein the first protruding piece and the second protruding piece are bent in opposite directions to each other in the plate thickness direction.

4. The vehicle door opening degree restricting mechanism according to claim 3 , wherein a thickness direction of the plate coincides with a vertical direction of the vehicle.

5. The vehicle door opening degree restricting mechanism according to claim 3 , wherein the embedded portion is branched into two portions in front of the protruding portion.

6. The vehicle door opening degree restricting mechanism according to claim 1 , wherein the protruding portion is bent at an acute angle so as to be folded back toward the base end portion.

7. a case fixed to a rear surface of a door side wall of a door having a door side wall attached via a hinge to a door opening formed in a vehicle body; a bracket attached to a portion of the door opening facing the door side wall; a lever made of a metal plate and a resin covering the plate, the lever being divided into a base end portion rotatably attached to the bracket, an intermediate portion continuous with the base end portion and extending so as to penetrate the door side wall and the case, and a stopper portion continuous with the intermediate portion, positioned inside the door, having a cross-sectional area larger than that of the intermediate portion, and determining the opening degree of the door; a lever manufacturing method for a vehicle door opening degree limiting mechanism, the lever being configured to limit the opening degree of the door by bringing an end face of the stopper portion on a base end side in the lever longitudinal direction into contact with the case, the plate includes an embedded portion extending from the inside of the base end portion to the inside of the stopper portion, and a protruding portion that is continuous with the embedded portion and protrudes outward from the tip of the stopper portion in the lever longitudinal direction, the protruding portion is bent so as to follow a surface of the stopper portion opposite to the end surface in the lever longitudinal direction, and holds the stopper portion from a tip side in the lever longitudinal direction, The lever manufacturing method includes: a plate intermediate forming step of forming a plate intermediate, which is an intermediate of the plate, and has the same shape as the plate except that a portion corresponding to the protruding portion extends linearly; a molding step of molding a lever intermediate, which is an intermediate of the lever, by injecting a resin between a surface of a portion of the plate intermediate corresponding to the embedded portion and a mold; a bending step of bending a portion corresponding to the protruding portion of the lever intermediate body along a surface of the lever intermediate body on a tip side in a longitudinal direction of the lever, after the molding step; A method for manufacturing a lever, comprising:

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