U.S. patent application number 10/600346 was filed with the patent office on 2004-02-12 for mirror base.
This patent application is currently assigned to MURAKAMI CORPORATION. Invention is credited to Aoyama, Kyoji, Okamoto, Syuuji.
Application Number | 20040026592 10/600346 |
Document ID | / |
Family ID | 30112900 |
Filed Date | 2004-02-12 |
United States Patent
Application |
20040026592 |
Kind Code |
A1 |
Okamoto, Syuuji ; et
al. |
February 12, 2004 |
Mirror base
Abstract
A mirror base according to the present invention secures
sufficient flexural strength of a support piece relative to a mount
piece thanks to a reinforcing core member buried across the mount
piece and the support piece, whereby the mount piece and support
piece do not have to be integrally molded of a high-rigidity resin
or die casting material, but can be integrally molded of a
lightweight, inexpensive resin material. Since the core member is
provided with mounting nut portions bordering a mounting surface of
the mount piece and integrally molded with the core member, there
is no need for a post-process of fixing mounting nut bushes or stud
bolts to mounting bosses, for example, by heating and press fitting
as needed before.
Inventors: |
Okamoto, Syuuji;
(Fujieda-shi, JP) ; Aoyama, Kyoji; (Fujieda-shi,
JP) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
MURAKAMI CORPORATION
12-25 Miyamoto-cho Shizuoka
Shizuoka-shi
JP
422-8569
|
Family ID: |
30112900 |
Appl. No.: |
10/600346 |
Filed: |
June 23, 2003 |
Current U.S.
Class: |
248/475.1 |
Current CPC
Class: |
B60R 1/06 20130101 |
Class at
Publication: |
248/475.1 |
International
Class: |
A47G 001/16 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 29, 2002 |
JP |
2002-220008 |
Claims
What is claimed is:
1. A mirror base comprising a mount piece for mounting on a car;
and a support piece projecting from the mount piece and adapted to
support a mirror body, the mount piece and the support piece being
integrally molded. of a resin, wherein a reinforcing core member is
buried inside across the mount piece and the support piece.
2. The mirror base according to claim 1, wherein the core member is
provided with a rib for enhancing flexural rigidity of the support
piece relative to the mount piece.
3. The mirror base according to claim 1, wherein the core member is
provided with a mounting portion bordering a mounting surface of
the mount piece to be mounted on the car.
4. The mirror base according to claim 2, wherein the core member is
provided with a mounting portion bordering a mounting surface of
the mount piece to be mounted on the car.
5. The mirror base according to claim 3, wherein said mounting
portion is a mounting nut portion.
6. The mirror base according to claim 3, wherein said mounting
portion is a mounting bolt portion.
7. The mirror base according to claim 4, wherein said mounting
portion is a mounting nut portion.
8. The mirror base according to claim 4, wherein said mounting
portion is a mounting bolt portion.
9. The mirror base according to claim 1, wherein the core member
comprises a continuous flange formed in a marginal region
thereof.
10. The mirror base according to claim 2, wherein the core member
comprises a continuous flange formed in a marginal region
thereof.
11. The mirror base according to claim 3, wherein the core member
comprises a continuous flange formed in a marginal region
thereof.
12. The mirror base according to claim 4, wherein the core member
comprises a continuous flange formed in a marginal region
thereof.
13. The mirror base according to claim 9, wherein said core member
is comprised of a pressed product.
14. The mirror base according to claim 10, wherein said core member
is comprised of a pressed product.
15. The mirror base according to claim 11, wherein said core member
is comprised of a pressed product.
16. The mirror base according to claim 12, wherein said core member
is comprised of a pressed product.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a mirror base for mounting
a mirror body on a car and, more particularly, to a mirror base
integrally molded of resin.
[0003] 2. Related Background Art
[0004] A mirror body of a car door mirror or the like is generally
mounted through a mirror base on a car. The mirror base is normally
comprised of a mount piece fixed to a door or the like of a car;
and a support piece laterally projecting from the mount piece aside
from the car and supporting the mirror base, which are integrally
molded of a resin material or a die casting material. In the mount
piece of the mirror base integrally molded of the resin material,
nut bushes or stud bolts for mounting to the car are fixed to
mounting bosses by such means as heating and press fitting in a
post-process.
SUMMARY OF THE INVENTION
[0005] The conventional mirror bases as described above had to be
integrally molded of the high-rigidity resin or die casting
material, in order to secure the flexural strength of the support
piece relative to the mount piece. In this case, since the
high-rigidity resin materials are generally expensive, there arises
a problem of high production cost. The die casting materials have a
problem of increase in weight, as compared with the resin
materials.
[0006] The present invention provides a mirror base that can secure
sufficient flexural strength of the support piece relative to the
mount piece, without being integrally molded of the high-rigidity
resin or die casting material.
[0007] A mirror base according to the present invention is a mirror
base comprising a mount piece for mounting on a car; and a support
piece projecting from the mount piece and adapted to support a
mirror body, which are integrally molded of a resin, wherein a
reinforcing core member is buried inside across the mount piece and
the support piece.
[0008] Since the mirror base according to the present invention has
the reinforcing core member buried across the mount piece and the
support piece, it can secure sufficient flexural strength of the
support piece relative to the mount piece. For this reason, the
mount piece and support piece do not have to be integrally molded
of a high-rigidity resin material, but they can be integrally
molded of an inexpensive resin material.
[0009] The core member forming the mirror base of the present
invention can be comprised of one selected from welded structures
of metal, pressed products, and die-cast products, or one selected
from high-rigidity resin molding and FRP (Fiber Reinforced
Plastics). The core member is preferably provided with a rib for
enhancing the flexural rigidity of the support piece relative to
the mount piece, because it permits reduction in thickness and
weight of the core member.
[0010] The core member is preferably provided with a mounting bolt
portion or a mounting nut portion bordering a mounting surface of
the mount piece, because it obviates the need for the
conventionally required post-process of fixing the mounting nut to
the mount piece by heating and press fitting.
[0011] Furthermore, the core member is preferably comprised of a
pressed product in which a continuous flange is formed in a
marginal region thereof, because the core member can demonstrate
high flexural rigidity while being light in weight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view showing the appearance of the
mirror base according to an embodiment of the present
invention.
[0013] FIG. 2 is a perspective view showing the structure of the
core member shown in FIG. 1.
[0014] FIG. 3 is an enlarged sectional view of a mounting nut
portion shown in FIG. 2.
[0015] FIG. 4 is a perspective view showing a first modification
example of the core member shown in FIG. 2.
[0016] FIG. 5 is a perspective view showing a second modification
example of the core member shown in FIG. 2.
[0017] FIG. 6 is a perspective view showing a third modification
example of the core member shown in FIG. 2.
[0018] FIG. 7 is a perspective view showing a fourth modification
example of the core member shown in FIG. 2.
[0019] FIG. 8 is a perspective view showing a fifth modification
example of the core member shown in FIG. 2.
[0020] FIG. 9 is a perspective view showing a sixth modification
example of the core member shown in FIG. 2.
[0021] FIG. 10 is a perspective view of a mount-piece core of the
core member shown in FIG. 9, from the outer surface side.
[0022] FIG. 11 is a perspective view of a support-piece core of the
core member shown in FIG. 9, from the bottom surface side.
[0023] FIG. 12 is a sectional view of a mounting nut portion
provided in the mount-piece core of the core member shown in FIGS.
4, 6, and 7.
[0024] FIG. 13 is a sectional view showing a mounting bolt portion
as a first modification example of the mounting nut portion shown
in FIG. 3.
[0025] FIG. 14 is a sectional view showing a mounting bolt portion
as a second modification example of the mounting nut portion shown
in FIG. 3.
[0026] FIG. 15 is a sectional view showing a mounting bolt portion
as a third modification example of the mounting nut portion shown
in FIG. 3.
[0027] FIG. 16 is a sectional view showing a mounting nut portion
as a fourth modification example of the mounting nut portion shown
in FIG. 3.
[0028] FIG. 17 is an exploded perspective view of the mounting nut
portion of the fourth modification example shown in FIG. 16.
[0029] FIG. 18 is a sectional view showing a mounting bolt portion
as a fifth modification example of the mounting nut portion shown
in FIG. 3.
[0030] FIG. 19 is an exploded perspective view of the mounting bolt
portion of the fifth modification example shown in FIG. 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Illustrative embodiments of the mirror base according to the
present invention will be described below with reference to the
drawings. Among the drawings referred to, FIG. 1 is a perspective
view showing the appearance of the mirror base according to an
embodiment, FIG. 2 a perspective view showing the structure of the
core member shown in FIG. 1, and FIG. 3 an enlarged sectional view
of a mounting nut portion shown in FIG. 2.
[0032] As shown in FIG. 1, the mirror base in the embodiment is
constructed as mirror base 1 of door mirror equipment which is to
be mounted on the door part of a car not shown. The mirror base 1
is comprised of a mount piece 1A for mounting on the door part of
the car; and a support piece 1B laterally projecting from the mount
piece 1A aside the car and adapted to support mirror body 2, which
are integrally molded of a resin, and reinforcing core member 3 is
buried inside across the mount piece 1A and the support piece
1B.
[0033] The mount piece 1A and support piece 1B are integrally
molded of an appropriate resin material by insert molding in a
state in which the core member 3 is set inside an injection molding
mold. The mount piece 1A is a portion to be mounted on an
unrepresented gusset plate disposed at the front corner part of the
door frame of the car, and is molded in an approximately triangular
thick-plate shape corresponding to the shape of the gusset plate.
The support piece 1B is formed in a thick-plate shape bent and
projecting from the lower part of the rear half of the mount piece
1A, and the angle of flection thereof is approximately
70-90.degree..
[0034] Here the core member 3 is comprised, for example as shown in
FIG. 2, of a pressed product of a steel plate in which a continuous
flange 3A is formed in a marginal region thereof. This core member
3 is formed as follows: a support-piece core 3C buried in the
support piece 1B is bent at the angle of approximately
70-90.degree., as the support piece 1B was, relative to a
mount-piece core 3B buried in the mount piece 1A with a projecting
surface of flange 3A inside.
[0035] The mount-piece core 3B of the core member 3 is provided,
for example, with three mounting nut portions 3D for mounting on
the gusset plate with bolts, which project on the exterior surface
side. Each mounting nut portion 3D is, as shown in FIG. 3, a
portion in which female screw 3D2 is threaded by tapping on the
inner periphery of cylinder 3D1 formed by burring and in which the
tip part of the nut portion borders a mounting surface 1A1 of the
mount piece 1A. Although in the illustrated example the tip part of
the mounting nut portion 3D projects out from the mounting surface
1A1, the mounting nut portion 3D may be formed so that the tip face
thereof is at almost the same level as the mounting surface
1A1.
[0036] On the other hand, as shown in FIG. 2, the support-piece
core 3C of the core member 3 is provided with shaft passing holes
3E for interconnection with arm part 2A of the mirror body 2 shown
in FIG. 1, which are formed, for example, at three positions. An
inflectional portion between the mount-piece core 3B and the
support-piece core 3C of the core member 3 is provided, for
example, with two beads 3F of an angle cross section projecting on
the interior surface side, which are formed as ribs for enhancing
the flexural rigidity.
[0037] The mirror base 1 of the embodiment constructed as described
above is mounted as follows: the mount piece 1A is mounted on the
gusset plate of the car by screwing bolts into the three mounting
nut portions 3D bordering the mounting surface 1A1 of the mount
piece 1A, from the gusset plate side of the car not shown. Then, in
this mounted state, the mirror body 2 is supported on the support
piece 1B projecting from the mount piece 1A (see FIG. 1).
[0038] Here the core member 3 itself, buried across the mount piece
1A and the support piece 1B of the mirror base 1 as shown in FIG.
1, has high flexural rigidity and it demonstrates much higher
flexural rigidity thanks to the flange 3A and the beads 3F as ribs
shown in FIG. 2. For this reason, the mirror base 1 is reinforced
by the core member 3 to secure the sufficient flexural strength of
the support piece 1B relative to the mount piece 1A, and the
support piece 1B can withstand the load of 30 kgf, for example.
[0039] Since in the mirror base 1 of the embodiment the core member
3 is comprised of the pressed product of the steel plate with high
flexural rigidity having the flange 3A and beads 3F as ribs, the
weight of the mirror base 1 can be reduced by decreasing the
thickness of the core member 3.
[0040] Since the core member 3 is integrally formed with the
mounting nut portions 3D bordering the mounting surface 1A1 of the
mount piece 1A, the production process thereof obviates the need
for the post-process of fixing the mounting nuts to the mount piece
by heating and press fitting as required in the conventional
example, whereby the production process can be simplified.
[0041] Particularly, in the mirror base 1 of the embodiment, since
the core member 3 is buried so as to secure the sufficient flexural
rigidity of the support piece 1B relative to the mount piece 1A,
the mount piece 1A and the support piece 1B do not have to be
integrally molded of the high-rigidity resin material, but they can
be integrally molded of an inexpensive, appropriate resin
material.
[0042] FIGS. 4 to 11 show modification examples of the core member
3 forming the mirror base 1 of the embodiment. The core member 4
shown in FIG. 4 is a pressed product in which flange 4A,
mount-piece core 4B, support-piece core 4C, shaft passing holes 4E,
and beads 4F, which correspond to the flange 3A, mount-piece core
3B, support-piece core 3C, shaft passing holes 3E, and beads 3F of
the core member 3 shown in FIG. 2, are integrally formed by
pressing.
[0043] The core member 4 is provided, for example, with a wide,
long bead 4G of an arcuate cross section, which is formed as a rib
for enhancing the flexural rigidity of the support-piece core 4C
relative to the mount-piece core 4B, across the mount-piece core 4B
and the support-piece core 4C. The mount-piece core 4B is provided
with hemispherically curved, embossed portions 4H for enhancing the
flexural rigidity, which project toward the interior. As shown in
FIG. 12, nuts 4J, replacing the mounting nut portions 3D shown in
FIG. 3, are welded to the outer surface of the mount-piece core
4B.
[0044] Since the core member 4 is provided with the large bead 4G
and embossed portions 4H (see FIG. 4) in addition to the flange 4A
and beads 4F, it can demonstrate much higher flexural rigidity and
surely secure the flexural strength of the support-piece core 4C
relative to the mount-piece core 4B, whereby it can surely
reinforce the mirror base 1, so as to further enhance the flexural
strength of the support piece 1B relative to the mount piece
1A.
[0045] The core member 5 shown in FIG. 5 is a pressed product in
which flange 5A, mount-piece core 5B, support-piece core 5C,
mounting nut portions SD, and beads SF, which correspond to the
flange 3A, mount-piece core 3B, support-piece core 3C, mounting nut
portions 3D, and beads 3F of the core member 3 shown in FIG. 2, are
integrally formed by pressing.
[0046] The core member 5 is provided with a bead 5G similar to the
bead 4G shown in FIG. 4, and the bead 5G is formed as a rib for
enhancing the flexural rigidity of the support-piece core 5C
relative to the mount-piece core 5B, across the mount-piece core 5B
and the support-piece core 5C. The support-piece core 5C is
provided with a shaft portion 5H, which replaces the shafts to be
inserted into the shaft passing holes 3E shown in FIG. 2. The shaft
portion 5H is of a large-diameter cylinder shape projecting upward
from the inner surface of the support-piece core 5C. The shaft
portion 5H may also be constructed by inserting a cylindrical shaft
of a separate part into a large-diameter shaft passing hole bored
in the support-piece core 5C.
[0047] This core member 5 can also demonstrate high flexural
rigidity thanks to the flange 5A, beads 5F, and bead 5G and secure
sufficient flexural strength of the support-piece core 5C relative
to the mount-piece core 5B, whereby it can reinforce the mirror
base 1, so as to secure the sufficient flexural strength of the
support piece 1B relative to the mount piece 1A.
[0048] The core member 6 shown in FIG. 6 is comprised of two parts:
mount-piece core 6A buried in the mount piece 1A (see FIG. 1); and
support-piece core 6B buried in the support piece 1B (see FIG. 1).
The mount-piece core 6A is a pressed product of a steel plate in
which a continuous flange 6C is formed in the marginal region
thereof, and the support-piece core 6B is made of a short,
rectangular steel pipe.
[0049] The support-piece core 6B is fitted in flange 6D along the
peripheral edge of an aperture formed in the lower part of the
mount-piece core 6A, and projects out on the inner surface side of
the mount-piece core 6A where the flange 6C projects. Shaft passing
holes 6E, similar to those 3E shown in FIG. 2, are formed through
and in an upper surface of the support-piece core 6B. Nuts 6F,
similar to those 4J, are welded to the outer surface of the
mount-piece core 6A on the other side than the flange 6C side, as
shown in FIG. 12.
[0050] Since this core member 6 is of the structure in which the
support-piece core 6B of the rectangular steel pipe with high
rigidity is fitted in the flange 6D of the mount-piece core 6A so
as to secure the sufficient flexural strength of the support-piece
core 6B relative to the mount-piece core 6A, it can reinforce the
mirror base 1, so as to secure the sufficient flexural strength of
the support piece 1B relative to the mount piece 1A.
[0051] The core member 7 shown in FIG. 7 is comprised of a pressed
product of a steel plate, in which the support-piece core 7B buried
in the support piece 1B (see FIG. 1) is bent at the angle of
approximately 70-90.degree. relative to the mount-piece core 7A
buried in the mount piece 1A (see FIG. 1). This core member 7 is
provided with a bead 7C extending longitudinally across the
mount-piece core 7A and the support-piece core 7B, as a rib for
securing the flexural rigidity of the support-piece core 7B
relative to the mount-piece core 7A. This bead 7C projects out on
the outer surface side of the mount-piece core 7A and support-piece
core 7B and, for example, in a horseshoe sectional shape so as to
form a trench on the inner surface side of the mount-piece core 7A
and support-piece core 7B, and it demonstrates extremely high
flexural rigidity against the load acting from the top on the
support-piece core 7B.
[0052] Flanges 7D, projecting in the same direction as the bead 7C,
are integrally formed in the portions other than the upper edge of
the mount-piece core 7A and the projection end of the support-piece
core 7B in the core member 7. Shaft passing holes 7E, similar to
those 3E shown in FIG. 2, are formed through and in the
support-piece core 7B. Nuts 7F similar to those 4J are welded to
the outer surface of the mount-piece core 7A, as shown in FIG.
12.
[0053] Since the bead 7C demonstrates the extremely high flexural
rigidity against the load acting from the top on the support-piece
core 7B and the flanges 7D also demonstrate some flexural rigidity
in collaboration therewith, the core member 7 can secure the
sufficient flexural strength of the support-piece core 7B relative
to the mount-piece core 7A and surely reinforce the mirror base 1,
so as to secure the sufficient flexural strength of the support
piece 1B relative to the mount piece 1A.
[0054] The core member 8 shown in FIG. 8 is a die-cast product, an
injection-molded product of a high-rigidity resin, or an FRP
product in which the mount-piece core 8A buried in the mount piece
1A (see FIG. 1) and the support-piece core 8B buried in the support
piece 1B (see FIG. 1) are integrally formed. The mount-piece core
8A is formed in an L-shaped thick block shape and the support-piece
core 8B in a thick plate shape. This support-piece core 8B projects
at the angle of approximately 70-90.degree. from the lower part
near the crook of the mount-piece core 8A.
[0055] Screw holes 8C as mounting nut portions are formed at three
positions in the both-end and middle crook regions of the
mount-piece core 8A. A cylindrical shaft portion 8D with a large
diameter, which replaces the shafts to be inserted into the shaft
passing holes 3E shown in FIG. 2, projects out on the upper surface
of the support-piece core 8B.
[0056] Since the mount-piece core 8A and support-piece core 8B are
integrally molded in the thick shape, the core member 8 can
demonstrate high flexural rigidity and secure the sufficient
flexural strength of the support-piece core 8B relative to the
mount-piece core 8A, whereby it can reinforce the mirror base 1, so
as to secure the sufficient flexural strength of the support piece
1B relative to the mount piece 1A.
[0057] The core member 9 shown in FIGS. 9-11 is a welded structure
of a metal plate, in which the support-piece core 9B buried in the
support piece 1B (see FIG. 1) is welded so as to project at the
angle of approximately 70-90.degree., to the lower part of the rear
half of the mount-piece core 9A buried in the mount piece 1A (see
FIG. 1). As shown in FIG. 10, flanges 9C for enhancing flexural
rigidity are welded so as to project on the outer surface side, to
the marginal region of the mount-piece core 9A. Three nut members
9D forming the mounting nut portions are welded to the outer
surface of the mount-piece core 9A. The flanges 9C are welded so as
to be continuous through the nut members 9D.
[0058] Ribs 9E, 9E for securing the flexural rigidity of the
support-piece core 9B relative to the mount-piece core 9A are
welded to the bottom surface of the support-piece core 9B, as shown
in FIG. 11. The ribs 9E, 9E extend along the projecting direction
of the support-piece core 9B and their base ends are welded to the
lower part of the inner surface of the mount-piece core 9A while
butting against it.
[0059] Since this core member 9 can demonstrate high flexural
rigidity thanks to the flanges 9C and ribs 9E, 9E and secure
sufficient flexural strength of the support-piece core 8B relative
to the mount-piece core 8A, it can reinforce the mirror base 1, so
as to secure the sufficient flexural strength of the support piece
1B relative to the mount piece 1A.
[0060] The. mirror base according to the present invention is not
limited to the embodiments described above. For example, the
mounting nut portions 3D of the mount-piece core 3B shown in FIG. 3
can be changed into the mounting bolt portions or mounting nut
portions as shown in FIGS. 13-19.
[0061] The mounting bolt portion 13 shown in FIG. 13 is a portion
in which a male screw 13B is threaded on the outer periphery of
cylinder 13A formed by burring. This mounting bolt portion 13 is
set through the gusset plate of the car not shown, and a nut is
screwed onto the tip part of the bolt portion, whereby the mount
piece 1A of the mirror base 1 is mounted on the gusset plate as
shown in FIG. 1.
[0062] The mounting bolt portion 14 shown in FIG. 14 is a portion
in which a bolt 14B is screwed from the inner surface side of the
mount-piece core into a mounting nut 14A, similar to the mounting
nut portion 3D shown in FIG. 3, so that the tip of bolt 14B
projects out from the mounting nut 14A.
[0063] The mounting bolt portion 15 shown in FIG. 15 is a portion
in which a bolt 15B is inserted from the inner surface side of the
mount-piece core into a bolt passing hole 15A bored in the
mount-piece core and is welded to the outer surface of the
mount-piece core.
[0064] The mounting nut portion 16 shown in FIGS. 16 and 17 is a
portion in which a rivet portion 16C of rivet nut 16B is inserted
from the outer surface side of the mount-piece core into a fitting
hole 16A bored in the mount-piece core and in which the tip of the
rivet portion 16C is caulked on the inner surface side of the
mount-piece core and around the fitting hole 16A, thereby fixing
the nut portion 16D of rivet nut 16B to the outer surface of the
mount-piece core.
[0065] The mounting bolt portion 18 shown in FIGS. 18 and 19 is a
portion in which a screw member 18B with an engaging piece 18A
being welded to one end thereof is inserted from the inner surface
side of the mount-piece core into a through hole 18C bored in the
mount-piece core and in which the engaging piece 18A is engaged
with a pair of catching pieces 18D, 18D formed by lancing and
bending on the inner surface side of the mount-piece core. The pair
of catching pieces 18D, 18D are arranged in point symmetry with
respect to the center of the through hole 18C so as to permit the
engaging piece 18A to be rotated for mounting or dismounting.
[0066] Since the mirror base according to the present invention
secures the sufficient flexural strength of the support piece
relative to the mount piece thanks to the reinforcing core member
inserted across the mount piece and the support piece, the mount
piece and support piece do not have to be integrally molded of the
high-rigidity resin or die casting material, and, they can be
integrally molded of a lightweight, inexpensive resin material.
* * * * *