WEATHER STRIP AND METHOD OF MANUFACTURING THE SAME

Abstract

A weather strip couples to a flange with curved parts of a sliding door of an automobile. The weather strip includes an installation base member, a hollow part, and an insert. The installation base member couples to the flange and includes an inner-cabin side wall, a first outer-cabin side wall, and a connecting wall. Part of the installation base member is cut out, to provide a cut-out part. The part couples to the curved parts. The cut-out part is subjected to die molding, to provide a die-molded part. The hollow part is integrally formed with the installation base member by extrusion molding. The insert is shaped in conformance with the curved parts and is embedded in the die-molded part with a plurality of concave shaped parts of the insert abutted with a plurality of pins of a die under the die molding.

Claims

1. A weather strip operably couplable to a flange of at least one of a peripheral edge of a panel of an automobile or a peripheral edge of a door opening of an automobile body of the automobile, the flange having curved parts, the panel being movable between at least two positions to open and close the opening, and the weather strip comprising: an installation base member operably couplable to the flange, the installation base member including an inner-cabin side wall, a first outer-cabin side wall, and a connecting wall which connects the side walls, part of the installation base member being cut out, to provide a cut-out part, the part being operably couplable to the curved parts, and the cut-out part being subjected to die molding using die-molding material, to provide a die-molded part; a hollow part integrally formed with the installation base member by extrusion molding; and an insert shaped in conformance with the curved parts, the insert having a plurality of concave shaped parts, the insert being embedded in the die-molded part, the plurality of concave shaped parts being configured to abut with a plurality of pins of a die under the die molding.

2. The weather strip as claimed in claim 1, wherein the plurality of concave shaped parts, which abut with the plurality of pins, are exposed from the die-molding material.

3. The weather strip as claimed in claim 1, wherein the insert has flat edges, to provide flat-shaped parts, and the flat-shaped parts are inserted into part of the installation base member, which is formed by extrusion molding and uncut, from the cut-out part, to arrange the flat-shaped parts on an outer-cabin side surface of the first outer-cabin side wall.

4. The weather strip as claimed in claim 1, further comprising a first hollow seal part on an outer-cabin side of the installation base member, formed by extrusion molding, and the first hollow seal part and the first outer-cabin side wall of the installation base member are cut out, to provide the cut-out part, the cut-out part is subjected to die molding, to provide a second hollow seal part formed by die molding and a second outer-cabin side wall formed by die molding with the insert arranged and embedded in the second outer-cabin side wall formed by die molding, and the second hollow seal part formed by die molding corresponds to the first hollow seal part and the second outer-cabin side wall formed by die molding corresponds to the first outer-cabin side wall of the installation base member.

5. The weather strip as claimed in claim 4, wherein the second hollow seal part formed by die molding includes an inclined wall formed by die molding and a second installation wall formed by die molding, the inclined wall formed by die molding inclines and extends toward an exterior of the automobile from part of the second outer-cabin side wall formed by die molding closer to the hollow part, the second installation wall formed by die molding connects with an end part of the inclined wall formed by die molding and extends toward an end part of the second outer-cabin side wall formed by die molding, and the inclined wall formed by die molding is curved in conformance with a member which is opposite the inclined wall formed by die molding.

6. The weather strip as claimed in claim 4, wherein the second outer-cabin side wall formed by die molding includes an inclined wall formed by die molding and a second installation wall formed by die molding, the inclined wall formed by die molding inclines and extends toward an exterior of the automobile from part of the second outer-cabin side wall formed by die molding closer to the hollow part, the second installation wall formed by die molding connects with an end part of the inclined wall formed by die molding and extends toward an end part of the second outer-cabin side wall formed by die molding, and the second installation wall formed by die molding has a hole for a clip.

7. The weather strip as claimed in claim 5, wherein the second outer-cabin side wall formed by die molding includes an inclined wall formed by die molding and a second installation wall formed by die molding, the inclined wall formed by die molding inclines and extends toward an exterior of the automobile from part of the second outer-cabin side wall formed by die molding closer to the hollow part, the second installation wall formed by die molding connects with an end part of the inclined wall formed by die molding and extends toward an end part of the second outer-cabin side wall formed by die molding, and the second installation wall formed by die molding has a hole for a clip.

8. The weather strip as claimed in claim 1, further comprising a sensor fixed in the hollow part, and when an object is disposed between the panel and the opening, and makes contact with the hollow part when the panel is moved towards a closed position, an electric signal provides an indication that the object is in the opening.

9. A method of manufacturing a weather strip, the weather strip being operably couplable to a flange of at least one of a peripheral edge of a panel of an automobile or a peripheral edge of a door opening of an automobile body of the automobile, the flange having curved parts, the panel being movable between at least two positions to open and close the opening, and the weather strip comprising: an installation base member operably couplable to the flange, the installation base member including an inner-cabin side wall, a first outer-cabin side wall, and a connecting wall which connects the side walls, part of the installation base member being cut out, to provide a cut-out part, the part being operably couplable to the curved parts, and the cut-out part being subjected to die molding using die-molding material, to provide a die-molded part; a hollow part integrally formed with the installation base member by extrusion molding; and an insert shaped in conformance with the curved parts, and the insert having a plurality of concave shaped parts, the method comprising: placing the weather strip, which has the cut-out part, between an upper die and a lower die; providing inner dies between the upper die and the lower die, the inner dies having a plurality of pins which protrude; arranging and fixing the insert in the cut-out part with the plurality of concave shaped parts abutted with the plurality of pins of the inner dies, the cut-out part being where the insert is embedded by die molding; pouring the die-molding material into the cut-out part; and subjecting the cut-out part to die molding.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0041] FIG. 1 is an enlarged perspective view of a weather strip according to an embodiment of the present invention coupling to a sliding door illustrated in FIG. 10;

[0042] FIG. 2 is an enlarged perspective view of the principal components of the weather strip illustrated in FIG. 1;

[0043] FIG. 3A is a side view of an insert embedded in the weather strip illustrated in FIG. 2; FIG. 3B is a front view of the insert;

[0044] FIG. 4 is an enlarged cross-sectional view taken along line IV-IV in FIG. 2;

[0045] FIG. 5 is an enlarged cross-sectional view taken along line V-V in FIG. 2;

[0046] FIG. 6 is an enlarged cross-sectional view of a die taken along line V-V in FIG. 2 with the weather strip according to the embodiment of the present invention under die molding;

[0047] FIG. 7 is an enlarged cross-sectional view of the die taken along line VII-VII in FIG. 2 with the weather strip according to the embodiment of the present invention under the die molding;

[0048] FIG. 8 is an enlarged cross-sectional view of the die taken along line VIII-VIII in FIG. 2 with the weather strip according to the embodiment of the present invention under the die molding;

[0049] FIG. 9 is an enlarged cross-sectional view taken along line IX-IX in FIG. 2;

[0050] FIG. 10 is a side view of an automobile with the sliding door that opens and closes a door opening of an automobile body of an automobile; and

[0051] FIG. 11 is an enlarged perspective view of a conventional weather strip coupling to the sliding door illustrated in FIG. 10.

DETAILED DESCRIPTION

[0052] Referring to the Drawings, a weather strip 30 according to an embodiment of the present invention will be described.

[0053] The weather strip 30 couples to a flange F of a sliding door 1 of an automobile. The flange F protrudes toward a front part of an automobile body of the automobile from a front edge of the sliding door 1 illustrated in FIG. 1. The sliding door 1 moves between at least two positions to open and close a door opening of the automobile body illustrated in FIG. 10. A sensor (pressure sensitive sensor) S is fixed in the weather strip 30 and detects an electric signal which provides an indication that the object is in the opening. The object includes part of a human body, e.g. fingers, hands, or legs between the sliding door 1 (may also be front door 2 or side door) and the opening. The flange F has a substantially S shape on a belt line BL in conformance with a shape of the sliding door 1. More specifically, the flange F has a curved part 1a and a curved part 1b. The curved part 1a extends between the belt line BL and an upper part of the flange F and has a convex shape that extends toward an interior of the automobile. The curved part 1b extends between the belt line BL and a lower part of the flange F and has a convex shape that extends toward an exterior of the automobile. When constituents or items correspond to those in prior arts, the same symbols are used. The “electric signal” includes a change by short between two core wires 31, 32, and a change in capacitance.

[0054] As illustrated in FIGS. 2 and 4, the weather strip 30 includes an installation base member 21, a hollow part 22, and the sensor S. The installation base member 21 directly couples to the flange F. The installation base member 21 includes an inner-cabin side wall 21a, a first outer-cabin side wall 21b, and a connecting wall 21c which connects the side walls 21a, 21b. The hollow part 22 is integrally formed with the installation base member 21 by extrusion molding. The hollow part 22 makes contact with the object when the object including the finger is disposed between a front end surface of the sliding door 1 and the opening. The front end surface is opposite the opening. The sensor S is fixed in the hollow part 22 and detects the electric signal which provides the indication that the object is in the opening. The hollow part 22 has two core wires, or electrode wires including stranded wires, 31, 32, rubber like elastic bodies 34, 35, and a space 33. The core wires 31, 32 extend in an upper-lower direction, or a direction parallel to the peripheral edge of the opening, and are embedded in the rubber like elastic bodies 34, 35. The rubber like elastic bodies 34, 35 have conductivity. The space 33 is positioned between the rubber like elastic bodies 34, 35. The installation base member 21 has a plurality of holding lips 24, 24 formed inside and a core 25 embedded. The core 25 has a substantially U-shaped cross section and increases rigidity of the installation base member 21. A first hollow (or lip-shaped) seal part 26 is provided on the first outer-cabin side wall 21b.

[0055] As illustrated in FIG. 2, part of the installation base member 21 is cut out, to provide a cut-out part K. The part couples to the curved parts 1a, 1b. In this embodiment, the first outer-cabin side wall 21b and the first hollow seal part 26 are cut out. The cut-out part K is subjected to die molding using die-molding material, to provide a die-molded part M. In FIGS. 2, 7, 8, and 9, a black side part of black-white triangles indicates a die-molded part and a white side part indicates an extrusion-molded part. An insert 50 is shaped in conformance with the curved parts 1a, 1b as illustrated in FIG. 3, and embedded in die-molded part M.

[0056] The insert 50 has a plurality of concave shaped parts 53, 54. The concave shaped parts 53 abut with first pins 103a of a first inner die 103, and the concave shaped parts 54 abut with second pins 104a of a second inner die 104 under the die molding to be discussed below.

[0057] The plurality of concave shaped parts 53, 54 include first concave shaped parts 53 illustrated in FIGS. 3 and 8 and second concave shaped parts 54 illustrated in FIGS. 3 and 7. The first concave shaped parts 53 are prepared by providing holes that pierce the insert 50 in an inner-cabin and outer-cabin direction. The second concave shaped parts 54 are prepared by providing protrusions 55, to arrange the second concave shaped parts 54 closer to a front part of the automobile body than the protrusions 55. The protrusions 55 extend toward the exterior of the automobile.

[0058] As illustrated in FIG. 3, the insert 50 has an upper edge 51 and a lower edge 52. The edges 51, 52 are flat, to provide flat-shaped parts, and have second protrusions 58 closer to interior of automobile. The edges 51, 52 are greater in width in a front-rear direction of the automobile body than thickness in an inner-cabin and outer-cabin direction. As illustrated in FIGS. 2, 5, and 6, the flat-shaped parts are inserted into an outer-cabin side part of the installation base member 21, which is formed by extrusion molding and uncut, from the cut-out part K, to arrange the flat-shaped parts on an outer-cabin side surface of the first outer-cabin side wall 21b. The upper edge 51 is inserted into an upper part of the outer-cabin side part of the installation base member 21 from the cut-out part K. The lower edge 52 is inserted into a lower part of the outer-cabin side part of the installation base member 21 from the cut-out part K. The second protrusions 58 extend toward an interior of the automobile as illustrated in FIG. 3, and abut with an end surface of the installation base member 21 (illustration omitted), which is uncut, to prevent the insert 50 from advancing too deep inside when the insert 50 is being inserted.

[0059] The cut-out part K is subjected to the die molding to be discussed below referring to FIGS. 7 and 8, to provide a second hollow seal part 26M formed by die molding and a second outer-cabin side wall 21bM formed by die molding. The second hollow seal part 26M corresponds to the first hollow seal part 26, formed by extrusion molding, and the second outer-cabin side wall 21bM corresponds to the first outer-cabin side wall 21b, formed by extrusion molding. The second hollow seal part 26M includes an inclined wall 26M1 formed by die molding and a second installation wall 26M2 formed by die molding. The inclined wall 26M1 inclines and extends toward the exterior of the automobile from part of the second outer-cabin side wall 21bM closer to the hollow part 22. The second installation wall 26M2 connects with, or extends from, an end part of the inclined wall 26M1 and extends toward an end part of the second outer-cabin side wall 21bM.

[0060] The insert 50 is embedded in the second outer-cabin side wall 21bM of the die-molded part M with parts exposed. More specifically, an inner-cabin flat surface 56 and the first concave shaped parts 53, which are provided on an inner-cabin side surface of the insert 50 and to be discussed below referring to FIGS. 7 and 8, are exposed from the die-molded part M, but are invisible. This is because the flange F, to which the second outer-cabin side wall 21bM couples, conceals the exposed parts.

[0061] In addition, the second concave shaped parts 54 and the protrusions 55, which are provided on an outer-cabin side surface of the insert 50 and to be discussed below referring to FIG. 7, are exposed from the die-molded part M, but are invisible. This is because the second hollow seal part 26M, provided closer to the exterior of the automobile, conceals the exposed parts.

[0062] The exposed parts on the inner-cabin side surface and the outer-cabin side surface of the insert 50, which are invisible, do not spoil appearance.

[0063] As illustrated in FIG. 7, the second installation wall 26M2 has holes CH for clips at regular intervals. The holes CH are provided by setting a third pin 105a of a third inner die 105 against the second inner die 104. As illustrated in FIGS. 7 and 8, the second installation wall 26M2 or the second outer-cabin side wall 21bM has a hole NH used to pull out the second inner die 104. The hole NH runs full length of the die-molded part M.

[0064] In some embodiments, the inclined wall 26M1 is curved as illustrated in FIG. 9 in conformance with the shape of the sliding door 1, which is opposite the inclined wall 26M1.

[0065] A handle knob 3 illustrated in FIG. 1 has depressions 3a, 3b. In some embodiments, the inclined wall 26M1 is curved as illustrated in FIGS. 1 and 9 in conformance with the depressions 3a, 3b, to prevent spoilage of appearance.

[0066] The above-structured weather strip 30 is formed by die molding by the following steps.

[0067] First, the first hollow seal part 26 as well as the first outer-cabin side wall 21b is cut out, to provide the cut-out part K as illustrated in FIG. 2. The first outer-cabin side wall 21b couples to the curved parts 1a, 1b when the weather strip 30, formed by extrusion molding, couples to the flange F as illustrated in FIG. 1. Also, as illustrated in FIG. 5, a cut-out part 26K is provided on a first installation wall 26a of the first hollow seal part 26, which remains uncut, to pull out an edge of the second inner die 104.

[0068] Next, as illustrated in FIGS. 6, 7, and 8, the weather strip 30, which has the cut-out part K, is positioned between an upper die 101 and a lower die 102 of a die 100. The die 100 includes the first inner die 103, the second inner die 104, and a third inner die 105 between the upper die 101 and the lower die 102. FIGS. 6, 7, and 8 indicate four directions of the weather strip 30 coupling to the flange F in parentheses, that is (interior of automobile), (exterior of automobile), (front), and (rear), as well as four directions of the die 100, that is up, low, left, and right.

[0069] As illustrated in FIG. 6, an end of the first inner die 103 is inserted in the installation base member 21 and comes into contact with the inner-cabin side wall 21a, the first outer-cabin side wall 21b, and the connecting wall 21c, to support the installation base member 21 inside the die 100. As illustrated in FIGS. 7 and 8, part of the first inner die 103 other than the end supports the installation base member 21 inside the die 100, and a lower side surface of the first inner die 103 forms part of the cavity used to form the second outer-cabin side wall 21bM.

[0070] As illustrated in FIG. 6, an end of the second inner die 104 is inserted in the first hollow seal part 26 and comes into contact with an inner surface of the first hollow seal part 26, to support the first hollow seal part 26 inside the die 100 and press and fix the lower edge 52 on the first outer-cabin side wall 21b.

[0071] As illustrated in FIGS. 7 and 8, part of the second inner die 104 other than the end is inserted between the first inner die 103 and the third inner die 105 and forms part of a cavity used to form a die-molded part, that is the second hollow seal part 26M. The second hollow seal part 26M is continuous with the first hollow seal part 26, formed by extrusion molding.

[0072] As illustrated in FIG. 8, the first inner die 103 has the first pins 103a at intervals. The first pins 103a protrude downward, that is toward the second inner die 104. As illustrated in FIG. 7, the second inner die 104 has the second pins 104a at intervals. The second pins 104a protrude upward, that is toward the first inner die 103. As illustrated in FIG. 7, the third inner die 105 has the third pins 105a at intervals. The third pins 105a protrude toward the second inner die 104.

[0073] Next, the insert 50, shaped in conformance with the curved parts 1a, 1b, is arranged in the cut-out part K in the cavity alongside of the shape of the curved parts 1a, 1b.

[0074] When the insert 50 is arranged alongside of the shape of the curved parts 1a, 1b, as illustrated in FIGS. 5 and 6, the upper edge 51 is inserted into an upper part on an outer-cabin side of the installation base member 21 from the cut-out part K in the cavity, and is pressed against an outer-cabin side surface of the first outer-cabin side wall 21b by an upper side surface of the second inner die 104. Also, the lower edge 52 is inserted into a lower part on the outer-cabin side of the installation base member 21 from the cut-out part K in the cavity, and is pressed against the outer-cabin side surface of the first outer-cabin side wall 21b by the upper side surface of the second inner die 104.

[0075] The insert 50 is arranged and fixed in the cut-out part K in the cavity with the first concave shaped parts 53 abutted with the first pins 103a as illustrated in FIG. 8, and with the second concave shaped parts 54 abutted with the second pins 104a as illustrated in FIG. 7.

[0076] The abutment in two different directions illustrated in FIGS. 7 and 8 arranges and fixes the insert 50 in a right-left direction of the cavity. Also, the inner-cabin flat surface 56 abuts with a lower side surface of the first inner die 103 as illustrated in FIGS. 7 and 8, and a first protrusion 57 closer to exterior of the automobile, illustrated in FIG. 3, abuts with the upper side surface of the second inner die 104 (illustration omitted). The abutment in two different directions illustrated in FIGS. 7, 8, and 3 arranges and fixes the insert 50 in an upper-lower direction of the cavity.

[0077] The insert 50, arranged and fixed in the right-left and upper-lower directions of the cavity, is prevented from misalignment under the pressure from injection of the die-molding material into the cavity. As illustrated in FIGS. 7, 8, the insert 50 also includes a front side protrusion 59, which extends diagonally toward the front part of the automobile body and toward the exterior. The front side protrusion 59, kept away from the first inner die 103 or the second inner die 104, is embedded in the die-molded part M without being exposed, to increase bonding strength of the insert 50 to the die-molded part M.

[0078] As illustrated in FIG. 7, the hole NH used to pull out the second inner die 104 from the second hollow seal part 26M runs full length of the die-molded part M. Also, the second installation wall 26M2 has the holes CH for clips (illustration omitted) at intervals to fix the weather strip 30 on the sliding door 1. The second installation wall 26M2 and the holes CH are formed by setting the third pin 105a against the second inner die 104, pouring the die-molding material into the die 100, and releasing the die-molded part M from the die 100.

[0079] Pouring the die-molding material into the die 100 and releasing the die-molded part M from the die 100 as discussed above forms the weather strip 30 illustrated in FIG. 2 with the die-molded part M, prepared by subjecting the cut-out part K to die molding.

[0080] As illustrated in FIGS. 7 and 8, the insert 50 of the method of manufacturing the weather strip 30 of this embodiment abuts with the first pins 103a and the second pins 104a under the die molding. This configuration fixes the insert 50. In addition, the upper edge 51 and the lower edge 52 are sandwiched and fixed between the first outer-cabin side wall 21b and the second inner die 104, which is inserted in the first hollow seal part 26. This configuration increases fixing force of the insert 50, to prevent misalignment of the insert 50 due to the pressure from injection of the die-molding material.

[0081] This configuration keeps appearance of the weather strip 30 unspoiled and prevents deterioration in sensor function due to the misalignment of the insert 50.

[0082] Parts of the insert 50 that abut with the first pins 103a and the second pins 104a are kept away from the die-molding material and exposed from the die-molded part M, but are invisible. This is because the second hollow seal part 26M conceals the exposed parts. This configuration keeps appearance unspoiled.

[0083] Material of the insert 50 and material of the die-molding material may have similar flexibility. In some embodiments, the insert 50 is made of PP and the die-molding material is made of TPO.

[0084] This allows the insert 50 and the die-molding material, as bonded together, to yield sense of integrity, and the weather strip 30 to be easier to handle. The die-molding material preferably has a hardness that falls within a range of 20 to 90 JISA, which is soft, of Japan Industrial Standards (JIS), and more preferably in a range of 40 to 90 JISA. If the hardness is less than 40 JISA, the die-molded part M can perform an insufficient function (including assemblability to the automobile body). If the hardness is less than 20 JISA, the die-molded part M performs the insufficient function. In some embodiments, the insert 50 is covered with another resin material including adhesive, to prevent infiltration of water into inner electric components or wiring. In this modification, the other resin material, which is as soft as or softer (lower in hardness) than the die-molding material, does not hamper the sense of integrity.

[0085] In some embodiments, the material of the insert 50 and the material of the die-molding material have compatibility. This allows the insert 50 and the die-molded part M to yield the sense of integrity, and the weather strip 30 to be easier to handle. If the insert 50 is to be covered by the other resin material including adhesive to prevent infiltration of water, the compatibility simplifies selection of the adhesive to bond with the insert 50 and the die-molding material firmly. In some embodiments, the material of the insert 50 and the material of the die-molding material are so similar in property as to fuse. This allows the insert 50 to adhere to the die-molding material closely under the die molding without using adhesive, and prevents infiltration of water into the inner electric components or wiring. It is to be noted that “compatibility” in a narrow sense indicates that the material of the insert 50 and the material of the die-molding material are so similar in property as to fuse. When one material is TPO, the other material is polypropylene, polyethylene, TPO, or TPE, which includes olefinic resin. Examples of TPE, which includes olefinic resin, include thermoplastic styrenic elastomer (TPS). When one material is TPS under the condition that TPS includes olefinic resin, the other material is compatible with the TPS and so similar in property as to weld or fuse like the aforementioned TPO.

[0086] In this embodiment, the insert 50 has three first concave shaped parts 53, which abut with the first pins 103a, and eight concave shaped parts 54, which abut with the second pins 104a, at intervals in the upper-lower direction, or the direction parallel to the peripheral edge of the opening, of the insert 50. Number or method of fixing the concave shaped parts 53, 54 is not limited. In this embodiment, it is only required that the concave shaped parts of the insert 50 abut with and the first pins 103a and the second pins 104a and are fixed, to prevent misalignment of the insert 50 under the die molding.

[0087] In this embodiment the weather strip 30 couples to the curved parts 1a, 1b of the flange F of the sliding door 1, which moves between at least two positions. In some embodiments, the weather strip 30 couples to curved parts of the flange F of the opening.

[0088] In some embodiments, the weather strip 30 couples to curved parts of the flange F of a back door or a sunroof.

[0089] In this embodiment, the sensor S is unified with the hollow part and detects the electric signal which provides the indication that the object is in the opening. In some embodiments, the sensor S is separable, not unified, and fixed in the hollow part separately.