pedal

Abstract

A pedal (1) comprises: a swing axis portion (3) provided on one end of a pedal arm (2); a tread plate (4) provided on the other end; and a clevis mounting portion (7) provided between the swing axis portion (3) and the tread plate (4). The pedal arm (2) has a first lateral surface (21) and a second lateral surface (22). In the clevis mounting portion (7), the first lateral surface (21) is located closer than the second lateral surface (22) to a straight line (L) connecting the point of intersection (P1) between the center plane (CP) of the pedal arm (2) and the swing axis portion (3) with a central portion (P2) of the tread plate (4). A metal insert (5) embedded in the pedal arm (2) has a first plate (51) located close to the first lateral surface (21) and a rear plate (50) extending from the rear edge of the first plate (51) toward the second lateral surface (22). A clevis pin mounting hole (70) penetrating through the clevis mounting portion (7) is offset in the axial direction of a swing axis (SA) to be closer to the first lateral surface (21).

Description

pedal

[0001] The present invention relates to a pedal having a resin-metal composite structure.

[0002] In recent years, there has been a demand for further weight reduction in vehicles from the viewpoint of reducing greenhouse gas emissions. For example, in order to reduce the weight of vehicle pedals, it has been considered to form pedals that have traditionally been made of metal out of resin. Patent Document 1 discloses technology related to resin pedals.

[0003] Japanese Patent Application Laid-Open No. 2004-13186

[0004] In many cases, pedals such as brake pedals and clutch pedals have a point of application (clevis mounting portion) that is offset in the direction of the pedal's swing axis from the line connecting the fulcrum, which is the center of the pedal's swing, and the point of application (pressure point) where the pedal force is applied. Resin pedals can be subject to significant torsional deformation due to the torsional moment generated by this offset when the pedal is operated.

[0005] An object of the present invention is to provide a pedal that can suppress torsional deformation during operation.

[0006] A pedal according to one aspect of the present invention includes a pivot shaft provided at one end of a pedal arm, a footplate provided at the other end of the pedal arm, and a clevis mounting portion provided between the pivot shaft and the footplate of the pedal arm. The pedal arm is formed from resin and a metal insert embedded within the resin along the longitudinal direction of the pedal arm. The pedal arm has a first side surface on one axial side of the pivot shaft and a second side surface on the other axial side. The first side surface is located closer to a line connecting the intersection of the axial center plane of the pedal arm and the pivot axis of the pivot shaft and the center of the footplate than the second side surface in the clevis mounting portion. The metal insert includes at least a first plate located closer to the first side surface than the second side surface, and a rear plate extending from the rear edge of the first plate toward the second side surface. A clevis pin mounting hole passing through the clevis mounting portion intersects with an extension plane of the first plate, and the clevis pin mounting hole is offset in the axial direction so as to be closer to the first side surface than the second side surface.

[0007] The pedal described above can suppress torsional deformation during operation.

[0008] FIG. 1 is a perspective view of a pedal according to a first embodiment, as seen from the right rear. FIG. 2 is a front view of the pedal according to the first embodiment. FIG. 3 is a left side view of the pedal according to the first embodiment. FIG. 4 is a right side view of the pedal according to the first embodiment. FIG. 5 is a perspective view of a metal insert according to the first embodiment, as seen from the right rear. FIG. 6 is a perspective view of a metal insert according to the first embodiment, as seen from the right front. FIG. 7 is a cross-sectional view taken along line VII-VII in FIG. 3. FIG. 8 is a cross-sectional view taken along line VIII-VIII in FIG. 3. FIG. 9 is a cross-sectional view of a pedal according to a second embodiment, corresponding to FIG. 7. FIG. 10 is a cross-sectional view of a pedal according to the second embodiment, corresponding to FIG. 8.

[0009] Pedals according to several embodiments will be described below with reference to the drawings. In the drawings, FR and RR indicate the front and rear in the longitudinal direction of the vehicle, respectively, LH and RH indicate the left and right in the width direction of the vehicle, and UP and DN indicate the upper and lower directions, respectively. In the following description, the left and right sides in the width direction of the vehicle, and the front, front side, rear, and rear sides in the longitudinal direction of the vehicle will be simply referred to as the "left side," "right side," "front," "front side," "rear," and "rear side," respectively. For ease of explanation, the relative positional relationships of the various parts of the pedal will be defined based on the state in which the pedal is attached to the vehicle. Furthermore, components having the same functions as those already described will be designated by the same reference numerals, and their description will be omitted.

[0010] <First embodiment> A pedal 1 according to a first embodiment will be described with reference to Figures 1 to 8. The pedal 1 is a brake pedal having a resin-metal composite structure, and as shown in Figures 1 to 4, includes a pedal arm 2, a pivot shaft 3, and a footplate 4 to which a pedal force, or operating force, is input by a vehicle occupant.

[0011] The pedal arm 2 extends rearward and downward from the pivot shaft 3 and is bent, for example, to the left at its lowest point, forming an L-shape. The pedal arm 2 is also called a pedal stem.

[0012] The swing shaft 3 is provided at the upper end of one end of the pedal arm 2 and supports the pedal arm 2 so that it can swing about a swing axis SA. The axial direction of the swing axis SA (hereinafter also referred to as the swing axis direction) is typically parallel to the vehicle width direction. Therefore, the pedal arm 2 and the foot plate 4 swing in the fore-and-aft direction of the vehicle about the swing axis SA.

[0013] As in the illustrated example, the swing shaft portion 3 may be formed as a hollow shaft protruding to the left and right from the upper end of the pedal arm 2. The hollow shaft has a through hole extending in the swing axis direction. A metal inner shaft (not shown) is inserted into the through hole. The inner shaft is fixed to the cabin-side surface of a bulkhead (not shown) via a bracket (not shown), and supports the swing shaft portion 3 so that it can rotate around the swing axis SA. The bulkhead is also called a dash panel.

[0014] The footplate 4 is a curved plate-like member provided at the lower end of the other end of the pedal arm 2, and its rear surface, which is the tread surface, is curved convexly upward and rearward. In this embodiment, the pedal arm 2, the swing shaft 3, and the footplate 4 are made of fiber-reinforced plastics (hereinafter referred to as FRP) and are formed integrally with the pedal arm 2 by injection molding. While there are no particular limitations on the reinforcing fibers of the FRP, in this embodiment, short fibers, which have excellent moldability, are used. Furthermore, there are no particular limitations on the material of the reinforcing fibers, and known reinforcing fibers such as glass fiber and carbon fiber can be used.

[0015] The pedal arm 2 is formed from a metal insert 5 and resin 6 (see FIG. 7). The metal insert 5 is embedded inside the resin 6 along the longitudinal direction of the pedal arm 2. The metal insert 5 is set in a mold as an insert when the pedal 1 is injection molded.

[0016] As shown in FIGS. 2 to 4 , the pedal arm 2 has a first side surface 21 on one side in the swing axis direction, that is, the left side, and a second side surface 22 on the other side in the swing axis direction, that is, the right side. As in the illustrated example, the first side surface 21 and the second side surface 22 may extend parallel to a plane perpendicular to the swing axis SA from the upper end of the pedal arm 2 to the bending start point at the bottom. The first side surface 21 and the second side surface 22 define the swing axis direction width W of the pedal arm 2 (see FIG. 2 ). That is, in the illustrated example, the thickness of the pedal arm 2 corresponds to the swing axis direction width W. Furthermore, in the range from the upper end of the pedal arm 2 to the bending start point at the bottom, the thickness direction of the pedal arm is parallel to the swing axis direction.

[0017] As shown in Figures 1 to 4, a clevis mounting portion 7 is provided between the swing shaft portion 3 and the foot plate 4 of the pedal arm 2. As in the illustrated example, a recess 7a may be formed on the second side surface 22 side of the clevis mounting portion 7. In the area where the recess 7a is formed, the thickness (or width in the swing axis direction) of the pedal arm 2 is locally reduced. Of the clevis mounting portion 7, the vertical plate portion 7b, whose right side surface is the bottom surface of the recess 7a and whose left side surface is a part of the first side surface 21, is offset toward the first side surface 21 in the swing axis direction and is located closer to the first side surface 21 than the second side surface 22.

[0018] When a stepping force is applied to the footplate 4 of the pedal 1, the pivot shaft 3 functions as the "fulcrum," the footplate 4 functions as the "point of effort," and the clevis mounting portion 7 functions as the "point of application." More specifically, the intersection P1 of the central plane CP of the pedal arm 2 in the pivot axis direction and the pivot axis SA functions as the "fulcrum," and the central portion P2 of the footplate 4, typically the center point of the footplate 4, functions as the "point of effort." The central plane CP is the central plane of the width W of the pedal arm 2 in the pivot axis direction (see FIG. 2). The central portion P2 of the footplate 4 is the center of gravity of the geometric shape of the tread surface of the footplate 4 when viewed from the front. Note that the pedal 1 is a brake pedal, and a greater stepping force acts on its footplate 4 when operated than on an accelerator pedal.

[0019] As shown in FIG. 8 , a clevis pin mounting hole 70 is formed in the clevis mounting portion 7. The clevis pin mounting hole 70 penetrates the resin 6 of the vertical plate portion 7b of the clevis mounting portion 7 in the pivot axis direction. Like the vertical plate portion 7b of the clevis mounting portion 7, the clevis pin mounting hole 70 is offset toward the first side surface 21 in the pivot axis direction and is located closer to the first side surface 21 than the second side surface 22. More specifically, a center 70C of the pivot axis width of the clevis pin mounting hole 70 is closer to the first side surface 21 than the second side surface 22 in the pivot axis direction. The center 70C is the midpoint of a line segment connecting a left opening center 70A, which is on one side of the clevis pin mounting hole 70 in the pivot axis direction, and a right opening center 70B, which is on the other side of the pivot axis direction, and is the "point of action" mentioned above.

[0020] As shown in FIG. 2 , in the clevis mounting portion 7, the first side surface 21 is located closer to the line L connecting the intersection point P1 and the center P2 than the second side surface 22. Therefore, as shown in FIG. 8 , the distance between the line L and an intersection point P3 between the central axis of the clevis pin mounting hole 70 (i.e., the central axis of the clevis pin 10) and the first side surface 21 is smaller than the distance between the line L and an intersection point P4 between the central axis of the clevis pin mounting hole 70 and the extended surface 22a of the second side surface 22. The distance between the line L and the intersection point P3 is the distance between the foot of a perpendicular line drawn from the line P3 to the line L and the intersection point P3, and the distance between the line L and the intersection point P4 is the distance between the foot of a perpendicular line drawn from the line P4 to the line L and the intersection point P4. As in the illustrated example, the intersection point P3 may coincide with the center 70A of the left opening of the clevis pin mounting hole 70. The extension surface 22 a of the second side surface 22 is a plane defined by the periphery of the recess 7 a formed in the second side surface 22 .

[0021] A clevis 9 is attached to the clevis mounting portion 7. The clevis 9 is provided at the rear end of an operation rod 8 of a brake booster (not shown). The operation rod 8 passes through the bulkhead so that force input to the operation rod 8 is transmitted to the brake booster attached to the front surface of the bulkhead. The central axis of the operation rod 8 is parallel to a plane perpendicular to the swing axis SA.

[0022] The clevis 9 is attached to the pedal arm 2 by a clevis pin 10 so as to be able to swing. The clevis pin 10 is inserted into a clevis pin attachment hole 70, and a cotter pin 11 is attached to the tip of the clevis pin 10 to prevent it from coming out of the clevis pin attachment hole 70. When a stepping force is input to the footplate 4 of the pedal 1, a forward force acts on the operation rod 8 via the clevis pin 10 and clevis 9 due to the positional relationship of the fulcrum, force point, and point of action. This force is boosted by the brake booster and transmitted to the brake master cylinder.

[0023] The metal insert 5 will be described in detail with reference to Figures 5 to 7. The metal insert 5 is made of, for example, a press-formed steel plate, and extends continuously from near the pivot shaft 3 to near the foot plate 4 within the resin 6 of the pedal arm 2. As in the illustrated example, the upper end of the metal insert 5 may be located above the pivot shaft SA, and the lower end may be located below the upper end of the foot plate 4.

[0024] The metal insert 5 of this embodiment includes a first plate 51, a second plate 52, and a rear plate 50 along its entire length and has a U-shaped cross section. The first plate 51 is disposed within the resin 6 of the pedal arm 2 closer to the first side surface 21 than the second side surface 22, and the second plate 52 is disposed within the resin 6 of the pedal arm 2 closer to the second side surface 22 than the first side surface 21. The first side surface 21, the first plate 51, the second plate 52, and the second side surface 22 are arranged in this order in the swing axis direction. As shown in the example, the first plate 51 and the second plate 52 may be located on opposite sides of the center plane CP and may be disposed equidistant from the center plane CP. Alternatively, both the first plate 51 and the second plate 52 may be parallel to a plane perpendicular to the swing axis SA. The rear plate 50 may extend from the rear edge of the first plate 51 toward the second side surface 22 and be connected to the rear edges of the first plate 51 and the second plate 52. The first plate 51 and the second plate 52 extend forward from the left and right edges of the rear plate 50, respectively.

[0025] 7 and 8 , the metal insert 5 is entirely covered with the resin 6. The leading edges of the first plate 51 and the second plate 52 are covered with the resin 6 over the entire length of the metal insert 5, and both surfaces of the first plate 51, the second plate 52, and the rear plate 50 are also continuously covered with the resin 6.

[0026] 8, clevis pin mounting hole 70 intersects with the extension plane of first plate 51, i.e., plane S1 including the thickness center plane of first plate 51, but does not intersect with the extension plane of second plate 52, i.e., plane S2 including the thickness center plane of second plate 52. Therefore, midpoint 70C of the line segment connecting opening center 70A and opening center 70B of clevis pin mounting hole 70 is located closer to plane S1 than to plane S2.

[0027] As shown in FIGS. 5 and 6 , a first notch 51a may be formed in the front edge of the first plate 51 to avoid interference with the clevis pin mounting hole 70. Furthermore, a second notch 52a may be formed in the front edge of the second plate 52 to avoid interference with the clevis 9 attached to the clevis mounting portion 7. The second notch 52a is larger than the first notch 51a. As shown in FIG. 4 , when viewed in the swing axis direction, the inner peripheral edge of the second notch 52a is located outside the periphery of the recess 7a, which in turn is located outside the outer peripheral edge of the clevis 9. Meanwhile, the inner peripheral edge of the first notch 51a is located inside the outer peripheral edge of the clevis 9 when viewed in the swing axis direction. Furthermore, semicircular third notches 51b, 52b may be formed in the upper edges of the first plate 51 and the second plate 52, respectively, to avoid interference with the swing shaft portion 3.

[0028] As shown in FIG. 8 , resin 6 is interposed between the front edge of the first plate 51 and the inner circumferential surface of the clevis pin mounting hole 70 in the first cutout 51a. This interposed resin 6 connects the resin 6 on both sides of the first plate 51 in the pivot axis direction, preventing the resin 6 from peeling off from the first plate 51. Meanwhile, the portion of the vertical plate portion 7b of the clevis mounting portion 7 located forward of the clevis pin mounting hole 70 is composed solely of resin 6, and the first plate 51 is not embedded therein. The load acting on the front inner circumferential surface of the clevis pin mounting hole 70 when the operation rod 8 is moved rearward is smaller than the load acting on the rear inner circumferential surface of the clevis pin mounting hole 70 when the operation rod 8 is moved forward. Therefore, the first plate 51 does not need to be embedded in the portion of the vertical plate portion 7b of the clevis mounting portion 7 located forward of the clevis pin mounting hole 70. This reduces the weight of the pedal 1.

[0029] The effects of the pedal 1 according to the first embodiment will be described.

[0030] (1) The pedal 1 has a resin-metal composite structure and includes a pedal arm 2, a swing shaft 3 provided on one end of the pedal arm 2, a footplate 4 provided on the other end of the pedal arm 2, and a clevis mounting portion 7. The swing shaft 3 supports the pedal arm 2 so that it can swing about a swing axis SA. The clevis mounting portion 7 is provided between the swing shaft 3 and the footplate 4 of the pedal arm 2. The pedal arm 2 is formed of resin 6 and a metal insert 5 embedded within the resin 6 along the longitudinal direction of the pedal arm 2. The pedal arm 2 has a first side surface 21 on one side of the swing axis SA in the swing axis direction and a second side surface 22 on the other side in the swing axis direction. Within the resin 6, the metal insert 5 has a first plate 51 positioned closer to the first side surface 21 than the second side surface 22, and a rear plate 50 extending from the rear edge of the first plate 51 toward the second side surface 22. In the clevis mounting portion 7, the first side surface 21 is positioned closer to a line L connecting a center P2 of the foot plate 4 and an intersection P1 between the center plane CP of the pedal arm 2 in the pivot axis direction and the pivot axis SA, than the second side surface 22. A clevis pin mounting hole 70 is formed in the clevis mounting portion 7, penetrating the clevis mounting portion 7 in the pivot axis direction, so as to intersect with the extension plane of the first plate 51. The clevis pin mounting hole 70 is offset in the pivot axis direction so that the clevis pin mounting hole 70 is closer to the first side surface 21 than the second side surface 22.

[0031] That is, in the pedal 1, the clevis pin mounting hole 70 is offset toward the first side surface 21, closer to the line L than the second side surface 22. Therefore, the distance between the clevis pin mounting hole 70 and the line L is smaller than when the clevis pin mounting hole 70 is positioned closer to the second side surface 22, and the torsional moment generated in the pedal arm 2 when a pedal force is input to the footplate 4 can be reduced. This suppresses torsional deformation of the pedal 1 during operation and prevents the resin 6 from peeling off from the metal insert 5. Furthermore, suppressing torsional deformation smooths the transmission of force to the operating rod 8 via the clevis pin 10 and the clevis 9, improving the feeling when operating the pedal.

[0032] Furthermore, in the pedal 1, the clevis pin mounting hole 70 is positioned so as to intersect with the extended surface of the first plate 51 of the metal insert 5. Therefore, when a stepping force is applied to the foot plate 4, the force can be transmitted more efficiently from the first plate 51 to the clevis pin 10 inserted through the clevis pin mounting hole 70 than when the clevis pin mounting hole 70 is positioned so as not to intersect with the extended surface of the first plate 51. In other words, a portion of the rearward load input from the clevis pin 10 to the clevis pin mounting hole 70 can be received by the first plate 51, thereby preventing the load from being borne solely by the resin 6.

[0033] Furthermore, in the pedal 1, the first plate 51 and the rear plate 50 form an L-shaped bend in the cross section of the metal insert 5, which improves the strength and rigidity of the pedal arm 2 and further suppresses torsional deformation of the pedal arm 2. This allows the cross-sectional dimensions of the pedal arm 2 to be made smaller, improving the degree of freedom in the layout of the pedal 1. Furthermore, the amount of resin used is reduced compared to when the pedal 1 is made solely from resin, making it possible to reduce the weight of the pedal 1.

[0034] (2) The first plate 51 may have a first notch 51a that avoids the clevis pin mounting hole 70. Compared to when a through hole for inserting the clevis pin 10 is formed in the first plate 51, the shape accuracy of the metal insert 5 and the positional accuracy required when setting the metal insert 5 in a mold during molding of the pedal 1 can be reduced, thereby improving the productivity of the pedal 1. Furthermore, compared to when the above-mentioned through hole is formed in the first plate 51, the weight of the metal insert 5 can be reduced, thereby further reducing the weight of the pedal 1.

[0035] (3) The metal insert 5 may further include a second plate 52 located within the resin 6, closer to the second side surface 22 than the first side surface 21, and equidistant from the center plane CP on the opposite side of the center plane CP from the first plate 51. The rear plate 50 may be connected to the rear edge of the first plate 51 and the rear edge of the second plate 52. The first plate 51, the rear plate 50, and the second plate 52 form a U-shaped cross section of the metal insert 5, further improving the strength and rigidity of the pedal arm 2. The second plate 52 may also include a second notch 52a that avoids the clevis 9 attached to the clevis mounting portion 7, and the clevis pin mounting hole 70 may not intersect with the extension plane of the second plate 52. The clevis pin mounting hole 70 may be positioned closer to the first side surface 21 while avoiding interference between the clevis 9 and the second plate 52. This further reduces the torsional moment that occurs in the pedal arm 2 when a tread force is applied to the footplate 4, thereby further suppressing torsional deformation of the pedal 1 during operation. In addition, by forming the second cutout 52a, the weight of the metal insert 5 can be further reduced, thereby making the pedal 1 even lighter.

[0036] Second Embodiment A pedal 1X according to a second embodiment will be described with reference to Figures 9 and 10. In the following description, only the configurations that differ from the first embodiment will be described, and descriptions of elements that have the same functions as elements already described in the first embodiment will be omitted.

[0037] The pedal 1X has the same configuration as the pedal 1, except that the metal insert 5X does not include the second plate 52. Therefore, the pedal 1X can achieve the above-mentioned effects (1) and (2). Furthermore, the pedal 1X can achieve even greater weight reduction because the metal insert 5X is composed of the first plate 51 and the rear plate 50.

[0038] The above-described embodiments are merely examples described to facilitate understanding of the invention. The technical scope of the invention is not limited to the specific technical matters disclosed in the above-described embodiments, but also includes various modifications, changes, alternative technologies, etc. that can be easily derived therefrom.

[0039] For example, in the above embodiments, FRP is used as the resin 6 to increase the strength and rigidity of the pedal 1, 1X, but a resin that does not contain reinforcing fibers can also be used as the resin 6. Also, while short fibers, which have excellent moldability, are used as the reinforcing fibers of the FRP in the above embodiments, long fibers can also be used in part or all of the resin 6. Furthermore, although the pedal 1, 1X in the above embodiments is molded by injection molding, it may be formed by a method other than injection molding.

[0040] 1,1X Pedal 2 Pedal arm 21 First side surface 22 Second side surface 3 Oscillating shaft portion 4 Foot plate 5,5X Metal insert 50 Rear plate 51 First plate 51a First cutout portion 52 Second plate 52a Second cutout portion 6 Resin 7 Clevis mounting portion 70 Clevis pin mounting hole 9 Clevis CP Center plane of pedal arm SA Oscillating axis P1 Intersection point between oscillation axis SA and center plane CP P2 Center portion of foot plate L Straight line connecting intersection point P1 and center portion P2

Claims

1. A pedal having a resin-metal composite structure, comprising: a pedal arm; a swing shaft provided on one end of the pedal arm and supporting the pedal arm so that it can swing around a swing shaft; a footplate provided on the other end of the pedal arm and to which an operating force is input by an occupant; and a clevis mounting portion provided between the swing shaft of the pedal arm and the footplate, wherein the pedal arm is formed from resin and a metal insert embedded within the resin along the longitudinal direction of the pedal arm, the pedal arm having a first side surface on one axial side of the swing shaft and a second side surface on the other axial side, the metal insert having at least a first plate located within the resin closer to the first side surface than the second side surface, and a rear plate extending from a rear edge of the first plate towards the second side surface, and the first side surface of the clevis mounting portion is located closer to a line connecting the intersection of the axial center plane of the pedal arm and the swing shaft and the center of the footplate than the second side surface, A pedal, wherein a clevis pin mounting hole penetrating the clevis mounting portion in the axial direction is formed so as to intersect with the extension surface of the first plate, and the clevis pin mounting hole is offset in the axial direction so that the clevis pin mounting hole is closer to the first side surface than to the second side surface.

2. A pedal according to claim 1, wherein the first plate has a first cutout that avoids the clevis pin mounting hole.

3. A pedal as claimed in claim 1 or 2, wherein the metal insert further has a second plate located inside the resin, closer to the second side surface than the first side surface, and on the opposite side of the central plane from the first plate, equidistant from the central plane; the rear plate is connected to the rear edge of the first plate and the rear edge of the second plate; the clevis pin mounting hole does not intersect with the extended plane of the second plate; and the second plate has a second cutout portion that avoids a clevis mounted to the clevis mounting portion.

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