Vehicle door opening regulation mechanism and method for manufacturing the lever

Abstract

To improve the durability of a tip 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 tip 5 of a lever 1, which is made of resin m, on the side of a base end in a lever longitudinal direction into contact with a case 10. The plate 2 includes a plate base end section 2a, a plate middle section 2b, and a plate tip section 2c. The plate 2 includes: a long hole 21 which penetrates a portion located from the plate tip section 2c to the plate middle section 2b in the plate 2 in a plate thickness direction, and extends in the lever longitudinal direction; and a transverse groove 22 which is a groove extending along a plate plane in the plate tip section 2c, and crossing a predetermined portion 2d1 in the plate tip section 2c, in a periphery section 2d surrounding the long hole 21, in the plate 2.SELECTED DRAWING: Figure 4

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] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a vehicle door opening degree restricting mechanism having a structure that can suppress the occurrence of residual stress at the tip 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 that is an insert-molded product made of a metal plate and a resin covering the plate, the lever being divided into a base end pivotally attached to the bracket, an intermediate portion continuous with the base end and extending so as to penetrate the door side wall and the case, and a tip end portion continuous with the intermediate portion, positioned inside the door, having a cross-sectional area larger than that of the intermediate portion, and limiting the opening degree of the door, wherein an end face of the tip end 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 limiting mechanism, the plate is divided into a plate base end portion located inside the base end portion, a plate intermediate portion located inside the intermediate portion, and a plate tip portion located inside the tip portion, and the plate has a long hole that penetrates the portion of the plate extending from the plate tip portion to the plate intermediate portion in the plate thickness direction and extends in the longitudinal direction of the lever, and a transverse groove that extends along at least one plate plane in the plate thickness direction in the plate tip portion and is a groove that crosses a predetermined portion of the plate tip portion of the peripheral portion surrounding the long hole in the plate. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a vehicle door opening degree limiting mechanism and a lever manufacturing method having a structure that can suppress the occurrence of residual stress at the tip of the lever and improve durability. [Brief explanation of the drawings]

[0009] [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 side view of the vehicle door opening degree limiting mechanism. [Figure 4] FIG. 2 is a top 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] FIG. [Figure 8] FIG. [Figure 9] 10A to 10C are diagrams illustrating an example of a lever manufacturing method for manufacturing a lever. [Figure 10] 10A to 10C are diagrams illustrating an example of a lever manufacturing method for manufacturing a lever. [Figure 11] FIG. 10 is a perspective view of a lever according to a modified example. [Figure 12] FIG. 10 is a perspective view of a lever according to another modified example. DETAILED DESCRIPTION OF THE INVENTION

[0010] 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.

[0011] 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 Fig. 2 being a perspective view, Fig. 3 being a side view (left side view), and Fig. 4 being a top 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 figures, 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.

[0012] 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 60.

[0013] 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.

[0014] 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).

[0015] 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.

[0016] The lever 1 is a main component that determines the opening degree of the door D, and is an insert-molded product 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.

[0017] 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 60, 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.

[0018] 1 to 4, the lever 1 is divided into a base end 3 that is rotatably attached to the bracket 60, an intermediate portion 4 that is continuous with the base end 3 and extends so as to penetrate the door side wall D1 and the case 10, and a tip end 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.

[0019] 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.

[0020] 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 3), and a cover through-hole 12a is opened in the case cover 12 (see FIG. 4). 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.

[0021] 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.

[0022] The bracket 60 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 60 is attached to a front edge portion (B11) of the door opening B1 in the vehicle front-rear direction.

[0023] The bracket 60 is made up of a bracket main body 61 and a lever pivot shaft 62. The bracket main body 61 is formed with a bolt insertion hole 61a and a shaft fitting hole 61b (see FIG. 3). A bracket fixing bolt 63 for fixing the bracket 60 to the door opening B1 is inserted into the bolt insertion hole 61a. The lever pivot shaft 62 extends parallel to the extension direction of the door pivot shaft H1 of the hinge H (here, the vehicle up-and-down direction), and is attached to the bracket main body 61 by fitting into the shaft fitting hole 61b of the bracket main body 61.

[0024] 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 tip 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 tip portion 5. An opening force (an 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 tip portion 5 on the base end side in the lever longitudinal direction, and an impact force (pressure) can act on the end face 5a of the tip portion 5 when the door is fully opened.

[0025] Specifically, in this embodiment, the end face 5a on the base end side of the lever longitudinal direction of the tip 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.

[0026] Next, the detailed structure of the lever 1 will be described with reference to FIGS.

[0027] Fig. 5 is a perspective view of lever 1, Fig. 6 is a perspective view of plate 2 of lever 1, Fig. 7 is a partially enlarged perspective view of plate 2, and Fig. 8 is a partially enlarged view of lever 1. The lever 1 shown in Fig. 5 is also an example of a lever manufactured by a lever manufacturing method described below. Figs. 6 and 7 show the state after resin m has been removed from the lever 1 shown in Fig. 5, i.e., only plate 2 is shown.

[0028] 2 to 5, the lever 1 is divided into the base end portion 3, the intermediate portion 4, and the tip 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 60 side) in the longitudinal direction of the lever, the tip 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 tip portion 5.

[0029] A fitting hole 3a is formed in the base end portion 3, and a lever rotation shaft portion 62 of the bracket 60 fits into the fitting hole 3a. An end portion of the plate 2 is located inside the base end portion 3, and the lever rotation shaft portion 62 penetrates the end portion of the plate 2. The base end portion 3 is rotatably attached to the bracket 60 via the lever rotation shaft portion 62.

[0030] The intermediate portion 4 has a rectangular cross section and extends from the base end 3 to the tip end 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.

[0031] 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.

[0032] 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. When the tip of each shoe 15a, 15b then 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 tip 5.

[0033] The tip portion 5 constitutes the end portion (tip portion) on the tip side in the longitudinal direction of the lever 1. As described above, the tip 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 the portion that determines the opening degree of the door D. The tip portion 5 functions as a stopper that determines the maximum opening degree of the door D.

[0034] In this embodiment, the tip portion 5 is made up of 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 tip 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 tip 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.

[0035] In this embodiment, the portion of the tip 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 tip 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.

[0036] In this embodiment, the plate thickness direction coincides with the vehicle vertical 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 tip portion 5 that abuts against the case 10 and is the portion of the tip 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 vertical direction). Here, the expanded portion 51 has a portion that protrudes upward relative to the upper surface of the intermediate portion 4 and a portion that protrudes downward relative to the lower surface of the intermediate portion 4 in the plate thickness direction.

[0037] 2 to 5, in this embodiment, the expanded portion 51 (the portion of the distal end 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 in the plate width direction relative to one side surface of the intermediate portion 4 (the right or left side surface when the door is closed) and a portion that protrudes slightly outward in the plate width direction relative to the other side surface of the intermediate portion 4 (the left or right side surface when the door is closed). The amount of protrusion of the expanded portion 51 relative to the intermediate portion 4 in the plate width direction is significantly smaller than the amount of protrusion of the expanded portion 51 relative to 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.

[0038] In other words, in this embodiment, the end surface 5a of the tip portion 5 on the base end side in the lever longitudinal direction, which abuts against the case 10, has a plate width direction protruding surface portion 5a1 that protrudes outward in the plate width direction from the side surface 4d of the intermediate portion 4 in the plate width direction (the left side surface and the right side surface when the door is closed) in the plate width direction. Furthermore, in this embodiment, the end surface 5a of the tip portion 5 on the base end side in the lever longitudinal direction has a plate thickness direction protruding surface portion 5a2 that protrudes outward in the plate thickness direction from the side surface 4e of the intermediate portion 4 in the plate thickness direction (the upper surface and the lower surface when the door is closed). The plate width direction protruding surface portion 5a1 cooperates with the side surface 4d of the intermediate portion 4 on the tip portion 5 side of the lever 1 to form a lever step in the plate width direction (lever shoulder). Similarly, the plate thickness direction protruding surface portion 5a2 cooperates with the side surface 4e of the intermediate portion 4 on the tip portion 5 side of the lever 1 to form a lever step in the plate thickness direction (lever shoulder).

[0039] Specifically, the end face 5a on the base end side in the lever longitudinal direction of the tip portion 5 that abuts against the case 10 is the end face on the intermediate portion 4 side (base end portion 3 side) in the lever longitudinal direction of the expanded portion 51, and is formed as a rectangular annular plane extending in the vehicle up-down direction. The opening force when the door is fully opened (the inertial force of the door D in the door opening direction) is received by the end face 5a on the base end side in the lever longitudinal direction of the tip portion 5 (the plate width direction protruding surface portion 5a1 and the plate thickness direction protruding surface portion 5a2), and a large impact force acts on these portions.

[0040] Next, the plate 2 of the lever 1 will be described in detail.

[0041] 5, the entire plate 2 is embedded in resin m. 5 and 6 show that the plate 2 is formed using a metal plate having a predetermined plate thickness t, as described above. The entire plate 2 is covered with resin m.

[0042] The plate 2 is divided into a plate base end portion 2a, a plate middle portion 2b, and a plate tip portion 2c from the vehicle body B side toward the door D side. The plate 2 is formed in the shape of a flat bar that extends linearly in approximately one direction.

[0043] The plate base end 2a is a portion of the plate 2 that is located inside the base end 3 of the lever 1. A lever rotation shaft 62 of a bracket 60 is inserted into the plate base end 2a.

[0044] Plate intermediate portion 2b is a portion of plate 2 located inside intermediate portion 4 of lever 1. Plate intermediate portion 2b connects plate base end portion 2a and plate tip end portion 2c. Plate intermediate portion 2b extends inside intermediate portion 4 of lever 1 over the entire longitudinal direction of intermediate portion 4, is formed in a generally band-like shape with a predetermined plate width, and extends linearly in generally one direction.

[0045] Plate tip portion 2c is a portion of plate 2 located inside tip portion 5 of lever 1. In this embodiment, the plate width of plate tip portion 2c is set wider than the predetermined plate width of plate middle portion 2b. In other words, plate tip portion 2c is formed wider in the plate width direction than plate middle portion 2b.

[0046] 6 and 7, the plate 2 has an elongated hole 21 and a transverse groove 22. In other words, the plate 2 is formed with the elongated hole 21 and the transverse groove 22. The elongated hole 21 and the transverse groove 22 form part of a flow path for the resin m during the manufacturing process of the lever 1, which is an insert-molded product.

[0047] The elongated hole 21 is a hole that penetrates the portion of the plate 2 from the plate tip portion 2c to the plate middle portion 2b in the plate thickness direction and extends in the lever longitudinal direction. In other words, the elongated hole 21 is formed close to the plate tip surface side of the plate 2. The elongated hole 21 extends, for example, from the plate tip portion 2c to near the midpoint in the plate longitudinal direction.

[0048] In this embodiment, the elongated hole 21 is opened so as to extend from a portion 211 of the elongated hole 21 that penetrates the plate tip end 2c toward the plate base end 2a. The opening width in the plate width direction of the portion 211 of the elongated hole 21 that penetrates the plate tip end 2c is set wider than the opening width in the plate width direction of a portion 212 of the elongated hole 21 that penetrates the plate intermediate portion 2b.

[0049] In this embodiment, the opening width of the elongated hole 21 in the plate width direction is set to narrow toward the base end in the lever longitudinal direction in a portion of the hole wall of the elongated hole 21 that includes the elongated-hole-side opening end of the first branch groove 23. In other words, the opening width of the elongated hole 21, which serves as a flow path for the resin m, narrows toward the downstream side in the flow direction, and the plate 2 has a narrowed portion 24 in the portion between the two first branch grooves 23.

[0050] The transverse groove 22 is a groove extending along at least one plate plane in the plate thickness direction at the plate tip portion 2c, and crosses a predetermined portion 2d1 at the plate tip portion 2c of the peripheral edge portion 2d that surrounds the elongated hole 21 in the plate 2. The peripheral edge portion 2d has a generally constant width except on the plate base end portion 2a side.

[0051] The transverse grooves 22 do not penetrate the plate 2 in the plate thickness direction, but constitute part of the main flow path of the resin m in the manufacturing process of the lever 1, which is an insert-molded product. In this embodiment, the transverse grooves 22 are formed on one plate plane and the other plate plane in the plate thickness direction at the predetermined portion 2d1 of the plate tip portion 2c. In other words, the transverse grooves 22 are formed on both the front and back of the plate 2.

[0052] In this embodiment, the predetermined portion 2d1 where the transverse groove 22 is formed is a portion of the peripheral edge 2d of the plate 2 located toward the tip end of the elongated hole 21 in the plate tip portion 2c in the lever longitudinal direction. In other words, one end of the transverse groove 22 opens to the plate tip surface, and the other end opens to the end of the hole wall of the elongated hole 21 in the plate 2 on the plate tip surface side. The transverse groove 22 is aligned with the elongated hole 21, extends from the plate tip surface toward the elongated hole 21, and is connected to the elongated hole 21. In other words, the elongated hole 21 is located on an extension line of the extension direction of the transverse groove 22. More specifically, in a plan view of the plate 2 seen from one side in the plate thickness direction, the elongated hole center line passing through the center of the elongated hole 21 in the plate width direction is located on an extension line of the groove center line passing through the center of the transverse groove 22 in the groove width direction.

[0053] Referring to FIG. 8 , in this embodiment, the lever 1, which is an insert-molded part, has a gate mark g formed by insert molding on the outer surface of the tip end portion 5, in a portion facing the outer opening end of the transverse groove 22. In FIGS. 3 to 5 , the gate mark g is not shown for clarity. The gate mark g has a shape corresponding to the shape of the opening end of the injection gate (injection gate G shown in FIGS. 9 and 10 , which will be described later) during the manufacturing process, and is, for example, circular in plan view. Specifically, the gate mark g remains in the shape of a cylinder with a slight height in the center of the tip end surface of the lever 1 on the door D side in plan view. The diameter of the gate mark g, for example, is the same as or approximately the same as the groove width of the transverse groove 22. Furthermore, in a plan view of the lever 1 viewed from one side in the plate thickness direction, the gate mark g is aligned with the transverse groove 22 and the elongated hole 21 and extends from the tip end surface of the lever 1 toward the transverse groove 22 and the elongated hole 21.

[0054] In this embodiment, the plate 2 has a first branch groove 23 in addition to the long hole 21 and the transverse groove 22. That is, the plate 2 has the first branch groove 23 formed therein.

[0055] The first branch groove 23 extends along at least one plate plane in the plate thickness direction at the plate tip portion 2c toward the plate width direction protruding surface portion 5a1 of the end face 5a of the tip portion 5, and is a groove that crosses a portion 2d2 (in other words, the plate step portion / plate shoulder portion) of the peripheral portion 2d surrounding the long hole 21 in the plate 2 that is located on the base end side of the lever longitudinal direction at the plate tip portion 2c.

[0056] Specifically, as described above, the plate width direction protruding surface portion 5a1 of the lever 1 cooperates with the side surface 4d of the intermediate portion 4 on the tip end 5 side of the lever 1 to form a lever step portion (lever shoulder portion) in the plate width direction. The first branched groove 23 is formed to extend from the elongated hole 21 side of the plate tip end 2c toward the lever step portion (lever shoulder portion) of the tip end 5. The plate width direction protruding surface portion 5a1 is formed on both sides in the plate width direction. Therefore, a first branched groove 23 for one plate width direction protruding surface portion 5a1 and a first branched groove 23 for the other plate width direction protruding surface portion 5a1 are formed.

[0057] Like the transverse groove 22, the first branch groove 23 does not penetrate the plate 2 in the plate thickness direction, and constitutes part of the flow path of the resin m during the manufacturing process of the lever 1. In this embodiment, the first branch grooves 23 are formed on the front and back of the plate 2 on both sides in the plate width direction. Specifically, the first branch groove 23 on one side in the plate width direction and the first branch groove 23 on the other side in the plate width direction extend so as to branch in two directions from the elongated hole 21 in the plate tip portion 2c in a plan view of the plate 2 seen from one side in the plate thickness direction, and the two first branch grooves 23, 23, parts of the elongated hole 21, and the transverse groove 22 constitute a Y-shaped flow path as part of the flow path of the resin m during the lever manufacturing process.

[0058] In this embodiment, each of the first branched grooves 23 is formed so as to increase in width from the center toward the outside in the plate width direction. That is, the width of each of the first branched grooves 23 increases from the long hole 21 side toward the outside in the plate width direction.

[0059] Next, a method for manufacturing lever 1 will be described with reference to Figures 5, 6, 8 to 10, etc. Figures 9 and 10 are diagrams for explaining an example of a method for manufacturing lever 1, and more specifically, Figures 9 and 10 are diagrams for explaining the insert molding process.

[0060] The lever manufacturing method includes a plate forming process and an insert molding process.

[0061] The plate forming step is a step of forming the plate 2 shown in FIG. 6 using a metal plate material having a predetermined plate thickness t.

[0062] The insert molding process is a process for integrally molding a plate 2 and a resin m. In the insert molding process, first, the plate 2 is positioned in a cavity C of a mold M of an injection molding machine, as shown in Fig. 9. Although Fig. 9 shows only a portion of the plate 2, in reality, the entire plate 2 is positioned in the cavity C of the mold M.

[0063] Next, in the insert molding process, as shown in Figure 10, resin m is injected between the surface of the plate 2 and the inner surface of the cavity C of the mold M through an injection gate G formed in the mold M (i.e., by injecting resin into the cavity C), thereby forming the lever 1, which is an insert molded product.

[0064] Specifically, some or most of the resin m injected from the injection gate G flows into the elongated hole 21 through the transverse groove 22 at the plate tip 2c, and the remainder of the resin m injected from the injection gate G flows around the plate tip 2c. Because the transverse groove 22 is provided near the injection gate G, the resin m injected from the injection gate G easily flows into the elongated hole 21. Here, the injection gate G, transverse groove 22, and elongated hole 21 are aligned, which effectively improves the flowability of the resin m into the elongated hole 21. For example, some or most of the resin m that flows into the elongated hole 21 via the transverse groove 22 flows directly within the elongated hole 21 toward the plate base end 2a, and the remainder of the resin m that flows into the elongated hole 21 via the transverse groove 22 flows from within the elongated hole 21 outward in the plate thickness direction and out of the elongated hole 21. Then, part or most of the resin m that is injected from the injection gate G and flows around the plate tip 2c (i.e., the outer region in the plate thickness direction or the outer region in the plate width direction within the cavity C) without passing through the transverse groove 22 flows around the plate 2 as it is, and the remainder of the resin m that has flowed around the plate tip 2c flows through the long hole 21 so as to penetrate the plate 2 within the cavity C or merges with the flow within the long hole 21.

[0065] Referring to FIG. 10 , at the plate tip 2c, a portion of the resin m that flows toward the plate base end 2a within the slot 21 is guided through the constricted portion 24 toward the plate base end 2a of the slot 21, as indicated by the arrow in the figure. At this time, a portion of the resin m that collides with the constricted portion 24 is guided out of the slot 21 through the first branch groove 23, as indicated by the arrow in the figure, and flows toward the portion that forms the widthwise end surface 5a1 of the end surface 5a of the tip 5 of the lever 1 in the cavity C (in other words, the lever step portion / the lever shoulder portion). The resin m then flows around the plate 2 and through the slot 21 to the periphery of the plate base end 2a, covering the entire plate 2. As a result, the resin m in a molten state before solidification reaches every corner of the cavity C. At this time, the amount of resin m injected by the injection molding machine has reached a predetermined value required to fill the space within the cavity C. In the insert molding process, the pressure of the resin m by the injection molding machine is then maintained at a predetermined constant value to prevent the resin m from flowing back through the injection gate G. This pressure holding state is maintained for a predetermined time. During this pressure holding state, the resin m gradually cools and hardens.

[0066] 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 tip 5 of the lever 1, which can be subjected to an impact force when the door is fully opened.

[0067] Regarding durability, in the lever 1 according to this embodiment and the lever manufacturing method for this lever 1, the fluidity of the resin m is improved by the elongated hole 21 and the transverse groove 22 of the plate 2 to effectively suppress the generation of residual stress inside the resin m at the tip portion 5 during the insert molding process. In other words, the fluidity of the resin m is improved by the elongated hole 21 and the transverse groove 22, so that the resin m fills every corner of the cavity C of the mold M. As a result, molding shrinkage of the resin is effectively suppressed, and the generation of residual stress inside the resin m is effectively suppressed. Furthermore, unlike conventional anchor pins that can prevent shrinkage of the resin m, only the flat plate tip portion 2c is embedded inside the tip portion 5 of the lever 1. As a result, the generation of residual stress inside the resin m at the tip portion 5 is more effectively suppressed.

[0068] Then, for example, when the lever 1 has hardened, it is removed from the mold M as shown in Figure 5. After this molding, a gate mark g, which is a trace of the injection gate G, remains on the tip surface of the lever 1 as shown in Figure 6. This completes the manufacturing of the lever 1.

[0069] In the vehicle door opening degree limiting mechanism 100 according to this embodiment, the plate 2 of the lever 1 has an elongated hole 21 that penetrates the plate 2 in the plate thickness direction from the plate tip 2c to the plate middle 2b and extends in the lever longitudinal direction. The elongated hole 21 extends along at least one plate plane in the plate thickness direction at the plate tip 2c and crosses a predetermined portion 2d1 at the plate tip 2c of the peripheral edge 2d surrounding the elongated hole 21. As a result, the elongated hole 21 and the crossing groove 22 in the plate 2 improve the fluidity of the resin m during the manufacturing process of the lever 1, which is an insert-molded product. The molten resin m before solidification reaches every corner of the cavity C, effectively suppressing molding shrinkage of the resin m and the generation of residual stress. Furthermore, applying a dwell pressure to the resin m before solidification effectively reduces the amount of molding shrinkage of the resin m. Furthermore, the interior of the tip 5 has a simple structure, which more effectively suppresses the generation of residual stress within the resin m of the tip 5. As a result, a decrease in durability due to residual stress is suppressed, and durability is improved. Also, most of the inside of tip portion 5, which receives the impact force when the door is fully opened, is occupied by resin m, which is likely to achieve high toughness. In other words, tip portion 5 of lever 1 is provided with a resin-rich portion that penetrates elongated hole 21 and covers plate tip portion 2c, so the impact force is effectively absorbed and alleviated by this resin-rich portion.

[0070] As described above, according to the vehicle door opening degree limiting mechanism 100 of this embodiment, it is possible to provide a vehicle door opening degree limiting mechanism 100 having a structure that can suppress the occurrence of residual stress in the tip portion 5 of the lever 1 and improve durability.

[0071] In this embodiment, the predetermined portion 2d1 where the transverse groove 22 is formed is a portion of the peripheral edge 2d located on the tip side of the elongated hole 21 in the plate tip portion 2c in the longitudinal direction of the lever. As a result, the elongated hole 21 is located on an extension line of the extension direction of the transverse groove 22, and the flowability of the resin m into the elongated hole 21 is more effectively improved.

[0072] In this embodiment, the lever 1 has a gate mark g formed by insert molding on the outer surface of the tip portion 5, in a portion facing the outer opening end of the transverse groove 22. This makes it easy to confirm that the lever 1 was manufactured by the above-described lever manufacturing method. That is, in the manufacturing process of this lever 1, the injection gate G is located near and faces the outer opening end of the transverse groove 22 of the plate 2, so that the resin m injected from the injection gate G easily flows into the elongated hole 21 through the transverse groove 22 of the plate 2, further improving the fluidity of the resin m in the longitudinal direction of the lever. In particular, the fluidity of the resin m immediately after injection (injection) is effectively improved.

[0073] In this embodiment, the plate 2 has a first branched groove 23 that extends along at least one plate plane in the plate thickness direction at the plate tip 2c toward the plate width direction protruding surface 5a1 and crosses a portion 2d1 (lever) of the peripheral edge 2d located on the lever longitudinal base end side of the plate tip 2c. This more reliably improves the resin fluidity of the lever step (lever shoulder) including the plate width direction protruding surface 5a1 of the lever 1 during the manufacturing process, resulting in improved durability. When the door is fully opened, an impact force (pressing force) acts on the lever step (lever shoulder) including the plate width direction protruding surface 5a1 of the lever 1, causing stress concentration. In contrast, in this embodiment, the durability of the lever 1 that can withstand stress concentration at the lever step can be easily ensured by the improvement in resin fluidity provided by the first branched groove 23 during the manufacturing process.

[0074] In this embodiment, the first branched groove 23 is formed so as to increase in width from the center side in the plate width direction toward the outside in the plate width direction, which further reliably improves the resin fluidity of the lever step portion.

[0075] 11, which is a perspective view of a lever 1 according to a modified example, a second branched groove 25 may be further formed in the plate 2. The second branched groove 25 extends along at least one plate plane in the plate thickness direction in the plate intermediate portion 2b, and crosses a portion of the peripheral edge portion 2d of the plate 2 located on the lever longitudinal base end side of the plate intermediate portion 2b from the center side in the plate width direction toward the outside in the plate width direction. The second branched groove 25 is formed so as to increase in width from the center side in the plate width direction toward the outside in the plate width direction.

[0076] Like the transverse groove 22 and the first branch groove 23, the second branch groove 25 does not penetrate the plate 2 in the plate thickness direction and constitutes part of the flow path of the resin m during the manufacturing process of the lever 1. In FIG. 11, the second branch grooves 25 are formed on the front and back of the plate 2 on both sides in the plate width direction. Specifically, the second branch groove 25 on one side in the plate width direction and the second branch groove 25 on the other side in the plate width direction extend so as to branch in two directions from the base end of the elongated hole 21 in a plan view of the plate 2 seen from one side in the plate thickness direction. The two second branch grooves 25, 25, the elongated hole 21, and the transverse groove 22 form a Y-shaped flow path as part of the flow path of the resin m during the lever manufacturing process. This improves the resin fluidity around the middle portion 4 and the base end portion 3 of the lever 1 during the lever manufacturing process.

[0077] In this embodiment and the modified example of Figure 11, the transverse groove 22 and each branch groove (23, 25) are formed on both plate planes (front and back) in the plate thickness direction of the plate 2, but this is not limited to this and it is sufficient if they are formed on one of the plate planes.

[0078] 12, which is a perspective view of a lever 1 according to another modification, the first branched groove 23 and the second branched groove 25 do not have to be formed in the plate 2. The elongated hole 21 and the transverse groove 22 suppress the occurrence of residual stress in the tip portion 5 of the lever 1 and improve durability.

[0079] The expanded portion 51 of the tip portion 5 is not limited to being formed wide in the vehicle vertical direction, but may also be formed wide in the vehicle width direction when the door is closed. In this case, the plate 2 may be embedded inside the resin m with the plate width direction parallel to the vehicle vertical direction. In addition, in this embodiment, the end face 5a of the tip portion 5 on the base end side in the lever longitudinal direction directly abuts against the case 10, but this is not limited thereto. For example, a rectangular annular cushion material may be attached to the end face 5a of the tip portion 5, and the end face 5a of the tip portion 5 may abut against the case 10 via the cushion material.

[0080] 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]

[0081] 1...lever, 2...plate, 2a...base end of plate, 2b...Intermediate part of the plate, 2c...tip of plate, 2d...periphery, 2d1...A predetermined portion at the tip of the plate in the peripheral portion, 2d2...A portion of the peripheral edge located on the base end side of the lever in the longitudinal direction at the tip of the plate, 21...long hole, 22...Transverse groove, 23...first bifurcation groove, 25...second bifurcation groove, 3...Proximal end, 4...middle part, 5...Tip part, 5a...end surface, 5a1...plate width direction protruding surface portion, 10…cases, 60...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 that is an insert-molded product made of a metal plate and a resin covering the plate, the lever being divided into a base end that is rotatably attached to the bracket, a middle portion that is continuous with the base end and extends so as to penetrate the door side wall and the case, and a tip portion that is continuous with the middle portion, is located inside the door, has a cross-sectional area larger than that of the middle portion, and determines the opening degree of the door; a longitudinal end face of the tip portion of the lever on a base end side thereof contacts the case, thereby defining an opening degree of the door; the plate is divided into a plate base end portion located inside the base end portion, a plate intermediate portion located inside the intermediate portion, and a plate tip portion located inside the tip portion, a longitudinal groove extending along at least one plate plane in the plate thickness direction at the plate tip and across a predetermined portion of the peripheral portion of the plate surrounding the longitudinal hole at the plate tip, the longitudinal groove being a groove that crosses the plate tip.

2. 2. The vehicle door opening degree restricting mechanism according to claim 1, wherein the predetermined portion is a portion of the peripheral edge portion that is positioned on a tip side in the lever longitudinal direction with respect to the elongated hole in the tip end portion of the plate.

3. 2. The vehicle door opening degree restricting mechanism according to claim 1, wherein the lever has a gate mark formed by insert molding on an outer surface of the tip end portion in a portion facing an outer opening end of the transverse groove.

4. the end surface of the tip portion has a plate width direction protruding surface portion that protrudes outward in the plate width direction from a side surface of the intermediate portion in the plate width direction, 2. The vehicle door opening degree limiting mechanism according to claim 1, wherein the plate extends along at least one plate plane in the plate thickness direction at the plate tip portion toward the plate width direction protruding surface portion and has a first branch groove that is a groove that crosses a portion of the peripheral edge portion that is located on the base end side of the plate tip portion in the longitudinal direction of the lever.

5. The vehicle door opening degree restricting mechanism according to claim 4, wherein the first branch groove is formed so as to increase in width from a center side in the plate width direction toward an outer side in the plate width direction.

6. 6. The vehicle door opening degree limiting mechanism according to claim 4, wherein the plate has a second branch groove that extends along at least one plate plane in the plate thickness direction at the plate intermediate portion and that traverses a portion of the peripheral portion that is located on the base end side of the lever longitudinal direction at the plate intermediate portion from the center side in the plate width direction toward the outside in the plate width direction.

7. The vehicle door opening degree restricting mechanism according to claim 6, wherein the second branch groove is formed so as to increase in width from a center side in the plate width direction toward an outer side in the plate width direction.

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