Door hole cover mounting structure manufacturing method

Abstract

To provide a manufacturing method for a door hole cover mounting structure that is excellent in cable assembly workability. [Solution] A door hole cover mounting structure (18) has a door hole (20) that penetrates an inner panel (4), and a door hole cover (22). The door hole cover has a cover main body (27), a cover outer periphery (28), an insertion hole (33) that can receive a cable (21), a passage (34) that connects the insertion hole and an outer edge (28A) of the cover outer periphery, and an opening / closing part (40) that is swingably provided on the cover outer periphery and swings to open and close the passage. A manufacturing method of the door hole cover mounting structure includes the steps of opening the opening / closing part and placing the cable in the insertion hole through the passage, applying a sealant (55) to the edge of the door hole, abutting the cover outer periphery and the opening / closing part against the edge of the door hole via the sealant, and joining the cover outer periphery to the inner panel.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a door hole cover mounting structure. [Background technology]

[0002] It is well known that door holes are provided in the inner panel of an automobile door to route cables. Door hole covers are provided in the door holes to prevent rainwater and the like from entering the interior of the vehicle. The door hole cover in Patent Document 1 includes a cover member having a through hole through which the cable can be inserted, a seal member provided on the periphery of the cover member, and a lid body having an insertion portion through which the cable can be inserted, which covers the through hole from the exterior of the vehicle.

[0003] The door hole cover of Patent Document 2 is a cylindrical plug that is inserted into a door hole. The door hole cover has a harness hole in the center for passing a harness through and a flexible tongue that opens and closes the harness hole. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2024-8659 [Patent Document 2] Japanese Patent Application Publication No. 9-309391 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in both the door hole covers of Patent Documents 1 and 2, when assembling a cable to the door hole cover, the cable must be inserted into the door hole cover from its end. Therefore, the cable cannot be assembled to the door hole cover when both ends of the cable are connected to other devices. Thus, conventional door hole covers have the problem of poor workability in assembling the cable to the door hole cover.

[0006] In view of the above background, an object of the present invention is to provide a method for manufacturing a door hole cover mounting structure that is easy to assemble cables. [Means for solving the problem]

[0007] In order to solve the above-mentioned problems, one aspect of the present invention is a method for manufacturing a door hole cover mounting structure (18) having a door hole (20) penetrating an inner panel (4) of a door (1) of an automobile, and a door hole cover (22) for closing the door hole, wherein the door hole cover comprises a cover main body portion (27) facing the door hole, a cover outer peripheral portion (28) provided along the outer periphery of the cover main body portion and overlapping the edge of the door hole when viewed in a direction along the axis of the door hole, and a cable (21) passing through the cover outer peripheral portion and connected to the door hole, and receiving the cable (21). a passage portion (34) connecting the insertion hole and the outer edge (28A) of the outer periphery of the cover; and an opening / closing portion (40) that is swingably provided on the outer periphery of the cover and swings to open and close the passage portion, and the method includes the steps of opening the opening / closing portion and placing the cable in the insertion hole through the passage portion, applying a sealant (55) to the edge portion of the door hole, abutting the outer periphery of the cover and the opening / closing portion against the edge portion of the door hole via the sealant, and joining the outer periphery of the cover to the inner panel.

[0008] According to this aspect, a manufacturing method of a door hole cover mounting structure with excellent cable assembly workability can be provided. An operator can place the cable in the insertion hole through the passage by operating the opening / closing part to open the passage. After the cable is placed in the insertion hole, the passage is closed by the opening / closing part, thereby preventing rainwater and the like from passing through the passage.

[0009] In the above aspect, the outer periphery of the cover has a first wall (35A) and a second wall (35B) that define the passage portion, the base end of the opening / closing portion has a hinge (41) that is swingably connected to the first wall, and the tip of the opening / closing portion has a locking portion (42) that locks to the end of the second wall on the inner panel side.

[0010] According to this aspect, the locking portion is locked to the end portion of the second wall on the inner panel side, so that the opening / closing portion maintains the passage portion in a closed state. [Effects of the Invention]

[0011] According to the above configuration, it is possible to provide a manufacturing method for a door hole cover mounting structure that is easy to assemble the cable. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view of a door hole cover mounting structure according to an embodiment; [Figure 2] A perspective view of the door hole cover mounting structure as seen from the outside of the vehicle. [Figure 3] A perspective view of the door hole cover mounting structure seen from inside the vehicle [Figure 4] Perspective view of the door hole cover [Figure 5] FIG. 1 is an enlarged perspective view showing a main part of a door hole cover; [Figure 6] Cross-sectional view of the door hole cover opening and closing section [Figure 7] Plan view of the door hole cover from the first side [Figure 8] FIG. 1 is a perspective view of a door hole cover with an opening / closing portion in an open position; [Figure 9] FIG. 10 is a perspective view showing a state in which a cable is attached to the door hole cover with the opening / closing part in the open position. DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, an embodiment of a manufacturing method for a door hole cover mounting structure will be described with reference to the drawings.

[0014] As shown in FIG. 1, an automobile door 1 has a door panel 2 as a framework member and a door trim 3 provided to cover the interior side of the door panel 2. The door panel 2 has an inner panel 4 and an outer panel 5 formed from steel plates. The inner panel 4 is disposed on the interior side of the outer panel 5, which forms the exterior surface of the vehicle body. The inner panel 4 is joined to the outer panel 5 at its front, bottom, and rear edges, excluding its top edge. A first space 7 is formed between the inner panel 4 and the outer panel 5.

[0015] A window glass 8 and a lifting / lowering device 9 for the window glass 8 are disposed in the first space 7. The window glass 8 moves up and down through an opening formed between the upper edge of the inner panel 4 and the upper edge of the outer panel 5. Weatherstrips, which are sealing members that come into sliding contact with the window glass 8, are provided on the upper edges of the inner panel 4 and the outer panel 5. A door latch device 11 that detachably engages a striker provided on the vehicle body is provided at the rear end of the first space 7.

[0016] The door trim 3 is made of a resin material and is disposed on the vehicle interior side of the inner panel 4. A second space 12 is formed between the door trim 3 and the inner panel 4. The inner panel 4 is provided with devices such as a door handle 14 for operating the door latch device 11, a window switch 15 for operating the lifting device 9, and a speaker.

[0017] As shown in FIGS. 1 and 2 , a door hole 20 is formed in the inner panel 4. The door hole 20 penetrates the inner panel 4 in the thickness direction. The door hole 20 connects the first space 7 and the second space 12. A cable 21 connecting each device passes through the door hole 20 and extends from the first space 7 to the second space 12. The cable 21 may be, for example, a control cable connecting the door handle 14 and the door latch device 11, or a wire harness connecting the window switch 15 and the lifting device 9.

[0018] 1 to 3, the door hole 20 is closed by a door hole cover 22. A structure in which the door hole cover 22 is attached to the inner panel 4 and the door hole 20 is closed by the door hole cover 22 is called a door hole cover attachment structure 18.

[0019] As shown in FIG. 4 , the door hole cover 22 is formed in a plate shape and has a first surface 22A facing the inner panel 4 and a second surface 22B opposite to the first surface 22A. The door hole cover 22 has a cover main body 27 and a cover outer peripheral portion 28 provided along the outer periphery of the cover main body 27. The cover outer peripheral portion 28 may be formed in an annular shape along the outer periphery of the cover main body 27. On the first surface 22A, the cover main body 27 protrudes toward the inner panel 4 beyond the cover outer peripheral portion 28, and a step 29 is formed at the boundary between the cover main body 27 and the cover outer peripheral portion 28. The step 29 improves the rigidity of the door hole cover 22. The step 29 may be formed in a shape that can fit into the door hole 20.

[0020] The door hole cover 22 covers the door hole 20 from the vehicle interior side of the inner panel 4. The cover main body 27 faces the door hole 20. The cover outer periphery 28 overlaps with the edge 30 of the door hole 20 when viewed from the direction along the axis of the door hole 20. That is, a portion of the cover outer periphery 28 faces the edge 30 of the door hole 20 and abuts against it via a sealant 55 (described later). More specifically, the cover outer periphery 28 faces the vehicle interior side surface 4A of the inner panel 4 that constitutes the edge 30 of the door hole 20 in the thickness direction of the cover main body 27. When viewed from the thickness direction of the cover main body 27, the door hole 20 is located inside the outer edge 28A of the cover outer periphery 28. That is, when viewed from the thickness direction of the cover main body 27, the entire door hole 20 overlaps with the door hole cover 22.

[0021] The door hole cover 22 has an insertion hole 33 and a passage portion 34 connected to the insertion hole 33. The insertion hole 33 passes through the cover outer periphery 28 to connect to the door hole 20 and is capable of receiving the cable 21. The passage portion 34 connects the insertion hole 33 to the outer edge 28A of the cover outer periphery 28. Specifically, the passage portion 34 passes from the insertion hole 33 through the cover outer periphery 28 and opens at the outer edge 28A of the cover outer periphery 28. That is, the passage portion 34 extends from the insertion hole 33 to the outer edge 28A of the cover outer periphery 28. The passage portion 34 penetrates the cover outer periphery 28 in the thickness direction. The insertion hole 33 and the passage portion 34 cooperate to form a recess 35. The recess 35 is recessed from the outer edge 28A of the cover outer periphery 28 toward the center of the door hole cover 22 and penetrates the door hole cover 22 in the thickness direction.

[0022] As shown in FIG. 5 , the cover outer periphery 28 has a first wall 35A and a second wall 35B that define the passage 34. The first wall 35A and the second wall 35B face each other at a distance. The first wall 35A and the second wall 35B extend parallel to each other. One end of each of the first wall 35A and the second wall 35B is connected to the outer edge 28A of the cover outer periphery 28. The other end of each of the first wall 35A and the second wall 35B is connected to a third wall 35C. The third wall 35C is formed into an arc-shaped concave surface. The other ends of the first wall 35A and the second wall 35B and the third wall 35C define the insertion hole 33.

[0023] The distance between the first wall 35A and the second wall 35B is formed to be larger than the diameter of the cable 21 so that the cable 21 can pass through the passage portion 34. On the other hand, it is preferable that the distance between the first wall 35A and the second wall 35B is close to the diameter of the cable 21 so that the gap between the cable 21 and the first wall 35A and the second wall 35B is small. On the other hand, it is preferable that the diameter of the third wall 35C is formed to be larger than the diameter of the cable 21 so that the cable 21 can pass through the insertion portion. On the other hand, it is preferable that the diameter of the third wall 35C is close to the diameter of the cable 21 so that the gap between the cable 21 and the third wall 35C is small.

[0024] 5 and 6, the cover outer peripheral portion 28 is provided with an opening / closing portion 40 that opens and closes the passage portion 34. The opening / closing portion 40 is swingably provided on the cover outer peripheral portion 28 and swings to open and close the passage portion 34. The base end of the opening / closing portion 40 has a hinge 41 swingably connected to the first wall 35A. The tip end of the opening / closing portion 40 has a locking portion 42 that locks with the end of the second wall 35B on the inner panel 4 side. The opening / closing portion 40 has a plate-shaped main body 43 to which the hinge 41 and the locking portion 42 are connected.

[0025] The thickness of the main body 43 is smaller than the thickness of the cover outer peripheral portion 28. The hinge 41 is preferably an integral hinge formed integrally with the main body 43 and the cover outer peripheral portion 28. The hinge 41 is thinner than the main body 43 and is flexible. The hinge 41 is disposed at the end of the first wall 35A on the first surface 22A side. The rotation axis of the hinge 41 preferably extends parallel to the intersection line of the first surface 22A and the first wall 35A.

[0026] The main body 43 of the opening-closing unit 40 swings or rotates about the hinge 41, thereby positioning the opening-closing unit 40 in a closed position and an open position. As shown in FIGS. 6 and 7 , when the opening-closing unit 40 is in the closed position, the main body 43 of the opening-closing unit 40 extends from the first wall 35A to the second wall 35B along the first surface 22A. When the opening-closing unit 40 is in the closed position, the passage 34 is closed by the opening-closing unit 40, preventing the cable 21 from passing through. As shown in FIG. 8 , when the opening-closing unit 40 is in the open position, the main body 43 of the opening-closing unit 40 extends parallel to the first wall 35A. When the opening-closing unit 40 is in the open position, the main body 43 may face the first wall 35A or may protrude outward from the first surface 22A. The hinge 41 preferably biases the opening-closing unit 40 to the closed position by a restoring force.

[0027] As shown in FIG. 6, the locking portion 42 is preferably a thin piece that protrudes parallel to the main body portion 43 from the tip of the main body portion 43. The locking portion 42 has higher flexibility than the main body portion 43. The locking portion 42 is preferably disposed on the same plane as the surface of the main body portion 43 on the first surface 22A side. When the opening / closing unit 40 is in the closed position, the locking portion 42 extends beyond the end of the second wall 35B and abuts against the first surface 22A. The locking portion 42 abutting against the first surface 22A restricts movement of the opening / closing unit 40 toward the first wall 35A.

[0028] 5, the main body 43 has an inner edge 43A and an outer edge 43B. The inner edge 43A cooperates with the first wall 35A, the second wall 35B, and the third wall 35C to define the insertion hole 33. The inner edge 43A is preferably formed in a concave arc shape to reduce the gap with the outer peripheral surface of the cable 21. The outer edge 43B extends along an imaginary line extrapolating the outer edge 28A of the cover outer periphery 28.

[0029] As shown in FIG. 3, the cover outer peripheral portion 28 has a plurality of fastening portions 51. Each fastening portion 51 is formed in a plate shape and extends in a direction away from the cover main body portion 27. Each of the plurality of fastening portions 51 abuts against the interior side surface 4A of the inner panel 4 and is fastened to the inner panel 4. The plurality of fastening portions 51 are fastened to the inner panel 4 by a plurality of fastening members 52. The plurality of fastening members 52 may be clips attached to the corresponding fastening portions 51. The plurality of fastening members 52 protrude from each of the fastening portions 51 toward the inner panel 4. As shown in FIG. 2, the plurality of fastening members 52 may be coupled to a plurality of coupling holes 53 formed in the inner panel 4.

[0030] The following describes a manufacturing method for the door hole cover mounting structure 18. The manufacturing method for the door hole cover mounting structure 18 includes the steps of opening the opening / closing part 40 and placing the cable 21 in the insertion hole 33 through the passage part 34, applying a sealant 55 to the edge part 30 of the door hole 20, abutting the cover outer periphery 28 and the opening / closing part 40 against the edge part 30 of the door hole 20 via the sealant 55, and joining the cover outer periphery 28 to the inner panel 4.

[0031] A specific example of a method for manufacturing the door hole cover mounting structure 18, i.e., a method for mounting the door hole cover 22 to the inner panel 4, is as follows. First, the worker places the cable 21 through the passage 34 and into the insertion hole 33. At this time, the worker may press the main body 43 of the opening / closing part 40 with the side of the cable 21 to move the opening / closing part 40 to the open position. This opens the passage 34, allowing the cable 21 to pass through the passage 34. The worker may also press the opening / closing part 40 with his or her finger to move the opening / closing part 40 to the open position.

[0032] Next, while keeping the opening / closing unit 40 in the open position, the worker moves the side portion of the cable 21 through the passage 34 into the insertion hole 33. As a result, the cable 21 is placed in the insertion hole 33, as shown in FIG. 9 . When the cable 21 is placed in the insertion hole 33, the side portion of the cable 21 moves away from the main body 43 of the opening / closing unit 40, and the opening / closing unit 40 moves toward the closed position due to a restoring force. A sealing member may be attached to a portion of the outer circumferential surface of the cable 21 that corresponds to the insertion hole 33, and the cable 21 may be press-fitted into the insertion hole 33 together with the sealing member. The sealing member seals the gap between the outer circumferential surface of the cable 21 and the edge of the insertion hole 33 (the first wall 35A, the second wall 35B, the third wall 35C, and the inner edge 43A). The sealing member may be formed, for example, from a foam material (sponge) and wrapped around the outer circumferential surface of the cable 21.

[0033] Next, the worker grasps the opening / closing unit 40 and places it in the closed position (see FIG. 7). At this time, the locking portion 42 deforms and passes over the end of the second wall 35B on the first surface 22A side, and is locked to the end of the second wall 35B on the first surface 22A side. That is, the locking portion 42 abuts against the first surface 22A. This restricts the movement of the opening / closing unit 40 toward the first wall 35A (the open position side).

[0034] Next, the worker applies a sealant 55 to the edge 30 of the door hole 20 on the interior side surface 4A of the inner panel 4. The sealant 55 may be vulcanized rubber or non-vulcanized rubber. The sealant 55 may be, for example, non-vulcanized butyl rubber. The worker applies the sealant 55 so as to surround the door hole 20 in a ring shape. Note that the step of applying the sealant 55 to the edge 30 of the door hole 20 may be performed before the step of placing the cable 21 in the insertion hole 33.

[0035] Next, the worker attaches the door hole cover 22 with the cable 21 attached to it to the door hole 20. At this time, the cable 21 moves axially within the insertion hole 33. As a result, the cover main body 27 faces the door hole 20, and the cover outer periphery 28 and the opening / closing part 40 abut against the edge 30 of the door hole 20 via the sealant 55. At this time, the cover main body 27 may be fitted into the insertion hole 33 to position the door hole cover 22 relative to the insertion hole 33. Also, each clip of each fastening part 51 engages with the coupling hole 53 of the inner panel 4. As a result, the door hole cover 22 is attached to the door hole 20, and the door hole 20 is closed. In this manner, the door hole cover mounting structure 18 is formed (see FIGS. 2 and 3).

[0036] In the door hole cover mounting structure 18, the locking portion 42 of the opening / closing portion 40 is sandwiched between the edge portion 30 of the door hole 20 and the first surface 22A. This maintains the opening / closing portion 40 in the closed position. When the sealant 55 is made of unvulcanized butyl rubber, the cover outer periphery 28 and the opening / closing portion 40 are bonded to the edge portion 30 of the door hole 20 by the sealant 55. The sealant 55 also maintains the opening / closing portion 40 in the closed position.

[0037] Because the passage 34 connects the insertion hole 33 and the outer edge 28A of the cover outer periphery 28, the worker can insert the middle portion of the cable 21 directly into the insertion hole 33. This improves the ease of assembling the cable 21 to the door hole cover 22. The worker can place the cable 21 in the insertion hole 33 through the passage 34 by operating the opening / closing part 40 to open the passage 34. After the cable 21 is placed in the insertion hole 33, the opening / closing part 40 closes the passage 34, thereby preventing rainwater and the like from passing through the passage 34. Because the opening / closing part 40 is formed integrally with the cover outer periphery 28, there is no need to assemble the opening / closing part 40 to the passage 34, and the opening / closing part 40 will not fall off from the passage 34. This also improves the ease of assembling the cable 21 to the door hole cover 22.

[0038] Although the description of the specific embodiment has been completed above, the present invention is not limited to the above embodiment and can be widely modified. For example, the insertion hole 33 may be formed in the cover main body 27. In this case, the passage 34 may cross the cover outer periphery 28 and be formed in the cover main body 27 as well. Furthermore, the opening / closing portion 40 may be extended to match the shape of the passage 34. [Explanation of symbols]

[0039] 1: Door 4: Inner panel 18: Door hole cover mounting structure 20: Door Hall 21: Cable 22: Door hole cover 27: Cover body 28: Outer periphery of cover 28A: outer edge 30: Edge 33: Insertion hole 34:Aisle section 35A: 1st wall 35B: 2nd wall 40: Opening and closing section 41: Hinge 42: Locking part 43: Main body 55: Sealant

Claims

1. A method for manufacturing a door hole cover mounting structure having a door hole penetrating an inner panel of a car door and a door hole cover that closes the door hole, The door hole cover is a cover main body portion facing the door hole; a cover outer periphery provided along the outer periphery of the cover main body and overlapping with an edge of the door hole when viewed from a direction along the axis of the door hole; an insertion hole that penetrates the outer periphery of the cover and is connected to the door hole and can receive a cable; a passage portion connecting the insertion hole and an outer edge of the outer periphery of the cover; an opening / closing part that is swingably provided on the outer periphery of the cover and swings to open and close the passage part, opening the opening / closing portion and placing the cable in the insertion hole through the passage portion; applying a sealant to the edge of the door hole; abutting the outer periphery of the cover and the opening / closing part against the edge of the door hole via the sealing agent; and a step of connecting the outer periphery of the cover to the inner panel.

2. the outer periphery of the cover has a first wall and a second wall that define the passage, a base end of the opening / closing portion has a hinge pivotally coupled to the first wall; The method for manufacturing a door hole cover mounting structure according to claim 1, wherein a tip of the opening and closing part has a locking part that is locked to an end part of the second wall on the inner panel side.

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