A CHEMICAL INJECTION STRUCTURE FOR A VEHICLE

FIELD OF INVENTION

The present invention relates to a chemical injection structure for a vehicle.

BACKGROUND OF THE INVENTION

It is known that a chemical injection structure for making an instrument panel. This structure includes an inner cylinder which is inserted into the instrument panel through the hole and injects a chemical into the space of the instrument panel, as disclosed in Japanese Patent Publication No. JP4359168B2 hereinafter called a prior art.

The inner cylinder includes a complicated structure at the tip end of the inner cylinder, so that the inner cylinder controls a chemical flow direction of a chemical inside the instrument panel. As such, since the prior art includes the complicated structure at the tip end of the inner cylinder, the complicated structure of the prior art results in a high cost of manufacturing the chemical injection structure.

Therefore, the development of the chemical injection structure, that reduces the cost of manufacturing the chemical injection structure as well as controls the chemical flow direction in an object space, is required.

CITATION LIST Patent Literature

PTL 1: Japanese Patent Publication No. JP4359168B2

SUMMARY OF THE INVENTION

It is an objective of the present inventions to provide a chemical injection structure for a vehicle, which reduces the cost of manufacturing the chemical injection structure as well as controls the chemical flow direction in an object space.

In order to achieve the above objective, an embodiment of the present invention provides a chemical injection structure for a vehicle comprising: a vehicle body; an injection hole which is positioned at the vehicle body and which a chemical passes through; a vehicle gap which is formed between the vehicle body and a wheelhouse panel; and a bracket which is positioned within the vehicle gap and is arranged so as to surround the injection hole when viewed from the longitudinal direction of the bracket, wherein the bracket includes a plurality of walls that are spaced from each other, and a reflecting portion that is positioned to face the injection hole.

According to the embodiment of the present invention, firstly, since the bracket includes the plurality of walls that are spaced from each other, and the reflecting portion that is positioned to face the injection hole, the chemical flows to the reflecting portion when the chemical is injected through the injection hole. And then, the chemical is reflected in the determined direction by the reflecting portion.

As such, the bracket with the reflecting portion can control the flow direction of the chemical without making the chemical injection structure into complicated structure. Consequently, the simple chemical injection structure enables to reduce cost of manufacturing the chemical injection structure.

Moreover, since the bracket with the reflecting portion can control the flow direction of the chemical, the chemical is filled inside the bracket. As such, the bracket is firmly fixed in place. Furthermore, since the bracket is firmly fixed in place, it is possible to reduce the occurrence of noise when the vehicle moves.

In the chemical injection structure of the embodiment of the present invention, the bracket further comprises a central plane bisecting a distance between a first end portion of the bracket on an injection hole side and a second end portion of the bracket being opposite to the first end portion, which is positioned between the injection hole and the reflecting portion.

According to the embodiment of the present invention, since the central plane of the bracket is positioned between the injection hole and the reflecting portion, the distance between the injection hole and the reflecting portion is made longer. As such, the space of the bracket between the first end portion and the reflecting portion increases and the space of the bracket between the reflecting portion and the second end portion decreases. Therefore, since the chemical can flow uniformly in the bracket, the chemical is filled inside the bracket so that the bracket is more firmly fixed in place.

In the chemical injection structure of the embodiment of the present invention, the reflecting portion comprises an upper end which is located at a position higher than a centerline of the injection hole.

According to the embodiment of the present invention, it is difficult that the chemical climbs over the upper end of the reflecting portion after the chemical arrives at the reflecting portion. Therefore, it is possible to reflect the chemical in the determined direction effectively. In the chemical injection structure of the embodiment of the present invention, the injection hole and the reflecting portion are positioned between the plurality of walls, and the plurality of walls are positioned in parallel when viewed from the top of the vehicle.

According to the embodiment of the present invention, since the reflecting portion is positioned between the walls, the bracket is formed into a room structure which effectively blocks the chemical within a room of the bracket. As such, there is no need to fill the chemical in the entire vehicle gap, thereby, it is possible to reduce amount of the chemical which is injected to the bracket.

Also, since the chemical injection structure includes the bracket with the room structure, it is possible to improve the strength around the vehicle gap.

Moreover, since the plurality of walls are positioned in parallel when viewed from the top of the vehicle, it is effective to control the chemical in the same direction.

In the chemical injection structure of the embodiment of the present invention, the reflecting portion further comprises a reflecting connection which is formed to connect to the plurality of walls.

According to the embodiment of the present invention, since the reflecting connection is formed to connect the plurality of walls and is included in the reflecting portion, it is easily to form the reflecting portion with the reflecting connection. Moreover, since the strength of the bracket improves, it is possible to inject the chemical with strong force.

In the chemical injection structure of the embodiment of the present invention, the bracket includes an injection panel which faces the injection hole, and the injection panel includes an opening portion which is aligned so as to face the injection hole.

Normally, a tool for the chemical injection is inserted into the injection hole of the vehicle body.

According to the embodiment of the present invention, since an injection panel faces the injection hole, and includes an opening portion which is aligned so as to face the injection hole, the tool for the chemical injection which passes through the injection hole can pass through the opening portion of the injection panel. Therefore, it is easily to set and control the tool at a correct position where the chemical injects in the correct direction.

In the chemical injection structure of the embodiment of the present invention, the injection panel further comprises an injection panel connection which is formed to connect to the plurality of walls.

According to the embodiment of the present invention, since an injection panel connection is formed to connect to the plurality of walls and is included in the injection panel, it is easily to form the reflecting panel with the injection panel connection. Moreover, the strength of the bracket improves, as well as it is possible to receive the tool for the chemical injection firmly.

In the chemical injection structure of the embodiment of the present invention, each of the plurality of walls includes a wall fixing portion that is formed at a lower end of the wall and connects with the wheelhouse panel.

According to the embodiment of the present invention, since each wall includes the wall fixing portion that is formed at the lower end of the wall, the strength of the wall improves.

Moreover, since the wall fixing portion is formed at the lower end of the wall and connects with the wheelhouse panel, the area where the wall with the wall fixing portion contacts the wheelhouse panel is larger than the area where the wall without the wall fixing portion contacts the wheelhouse panel. Therefore, the bracket can be stably stood on the wheelhouse panel.

In the chemical injection structure of the embodiment of the present invention, the bracket includes at least a wall connection which extends to connect between the plurality of walls.

According to the embodiment of the present invention, since at least a wall connection extends to connect between the plurality of walls, the strength of the wall improves. Therefore, it is possible to inject the chemical with strong force.

Moreover, in case that the wall connection is firmed to connect with the wheelhouse panel, at least a connect area where the at least a wall connection contacts the wheelhouse panel is larger. Therefore, it is possible that the strength of the bracket and the wheelhouse panel which correspond with the connected area improves.

In the chemical injection structure of the embodiment of the present invention, the bracket comprises a reflecting connection which is included in the reflecting portion and formed to connect to the plurality of walls, an injection panel connection which is included in the injection panel and formed to connect to the plurality of walls, and at least one wall connection which extends to connect between the plurality of walls, and reinforcement portions are formed between the reflecting connection and the wall, between the injection panel connection and the wall, and between the at least one wall connection and the wall.

According to the embodiment of the present invention, since the reinforcement portions are formed between the reflecting connection and the wall, between the injection panel connection and the wall, and between the at least one wall connection and the wall, the strength of the wall improves. Therefore, it is possible to inject the chemical with strong force. Moreover, in case that the reflecting connection, and the injection panel connection, and the at least one wall connection are firmed to connect with the wheelhouse panel, connect areas where the reflecting connection, and the injection panel connection, and the at least one wall connection contact the wheelhouse panel are stronger. Therefore, it is possible that the strength of the bracket and the wheelhouse panel which correspond with the connected area is improved.

In the chemical injection structure of the embodiment of the present invention, a center portion of each of the wall connection, the reflecting connection and the injection panel connection includes a ridge portion which is formed in a ridge shape.

According to the embodiment of the present invention, since the center portion of each of the wall connection, the reflecting connection and the injection panel connection is formed in a ridge shape, the strength of the wall connection, the reflecting connection and the injection panel connection furthermore improves.

BRIEF DESCRIPTION OF DRAWINGS

The principle of the present invention and its advantages will become apparent in the following description taking in consideration with the accompanying drawings in which:

FIG.1 is a left side view of the rear-end of a vehicle when being seen through a vehicle body, for the purpose of explaining a chemical injection structure according to an embodiment of the present invention;

FIG.2 is an explanatory view about the relation between the chemical injection structure and an injection hole, when being seen through the vehicle body;

FIG. 3 is an explanatory view about a state that a chemical injection tool is set to the predetermined position;

FIG. 4 is a top view of a bracket of the chemical injection structure;

FIG. 5 is a side view of the bracket of the chemical injection structure;

FIG. 6 is a top view of the chemical injection structure with the chemical flow direction, when being seen through an outer panel of the vehicle body;

FIG. 7 is a cross sectional view of the chemical injection structure taken along the line VII-VII of FIG.3.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Hereinafter, an embodiment of the present invention will be described in detail with reference to FIG. 1 to FIG. 7. In the following detailed description, relative positional terms such as " front" , " rear" , “ upper” , “ lower” , " top" and " bottom" correspond to those directions considered from the vantage point of a vehicle driver, seated in the driver's seat.

FIG.l and FIG.2 show a chemical injection structure 2 for a vehicle 1 including a vehicle body 10, an injection hole 20, a vehicle gap 40 which is formed between the vehicle body 10 and a wheelhouse panel 30, and a bracket 50 which is positioned within the vehicle gap 40.

The vehicle body 10 is fundamental panel structure that is assembled to a frame structure, side frames, cross members, and pillars that are connected by the joints. The vehicle body 10 includes an outer panel 10a that is positioned above the wheelhouse panel 30 which is provided to cover the wheel.

The wheelhouse panel 30 is provided rearward the entrance. The wheelhouse panel 30 is formed in an upwardly curved shape to house an associated wheel (not shown).

The wheelhouse panel 30 and the vehicle body 10 are the metal panels that are joined to each other and the vehicle gap 40 is generated as the empty room or space between the wheelhouse panel 30 and the vehicle body 10. As the vehicle gap 40 is located near the wheel, there is a possibility that it allows noise, especially the road noise generated by vehicle’ s tires moving on the surface of the road, to transmit to the cabin.

Since the occurrence of noise is resonated in the vehicle gap 40, the bracket 50 is provided within the vehicle gap 40 and filled with the chemical. The chemical functions as a barrier structure for blocking noise passing through the vehicle gap 40 and into the cabin. The example of the chemical is a resin or a foaming material. After injection, the chemical expands and firmly fills in the area of the bracket 50. In order to fill the bracket 50 with the chemical, the injection hole 20 is provided.

The injection hole 20 is positioned from the inner side of the vehicle body 10, enabling the chemical to be injected through. The bracket 50 is arranged so as to surround the injection hole 20 when viewed from the longitudinal direction of the bracket 50. FIG.3 shows a state that a chemical injection tool 4 is set so as to inject the chemical through the injection hole 20 to the bracket 50.

When the vehicle gap 40 is blocked by the bracket 50 filled with the chemical, most of the incident sound wave is reflected back, and a few sound waves pass through. Thus, it is difficult for the sound wave to continuously propagate in the vehicle gap 40, achieving the purpose of sound insulation.

Referring to FIG.4 and FIG.5, the structure of the bracket 50 for this embodiment will be explained. The bracket 50 includes a plurality of walls 52, 52 that are spaced from each other, and a reflecting portion 54 to face the injection hole 20. The reflecting portion 54 includes an erection wall 54b and a reflecting connection 60. The erection wall 54b is formed to extend from the reflecting connection 60 towards the upper direction of the bracket 50. When viewed from the side view of the bracket 50, the erection wall 54b has an approximately rectangular shape.

Preferably, the bracket 50 is fixed within the vehicle body 10 and the wheelhouse panel 30 by welding. However, it is not limited solely to welding, but can be in any type of fasteners used which are connected somehow of two sections, such as screws, rivets or bolts shooting. In addition, the bracket 50 is firmly fixed in place resulting from the chemical which is injected into the bracket 50 in the liquid state and then distributed uniformly along the shape of the bracket 50, once the chemical is turned from liquid into solid, it will push the bracket 50 to fix firmly with its surrounding parts. Therefore, it is possible to reduce the occurrence of noise when the vehicle moves. Moreover, the bracket 50 can be manufactured easily as its structure is simplified, enabling to reduce the manufacturing cost and time.

The bracket 50 further includes a first end portion 56 and a second end portion 58 being opposite to the first end portion 56. The first end portion 56 is arranged on the injection hole side. As shown in FIG.4, a central plane CP bisects a distance between the first end portion 56 and the second end portion 58 and positioned between the injection hole 20 and the reflecting portion 54, and positioned near the reflecting portion 54. For example, the distance from the central plane CP to the reflecting portion 54 is shorter than the distance from the central plane CP to the first end portion 56.

With this arrangement, the distance from the first end portion 56 to the reflecting portion 54 is longer than the distance from the reflecting portion 54 to the second end portion 58. Without the reflecting portion 54, the chemical having a high viscosity will flow directly to hit the second end portion 58 and cannot spread or divert the flow back to the first end portion 56 to fill the space near the first end portion 56. On the other hand, with the reflecting portion 54, the chemical will flow to hit the reflecting portion 54 and then some part will divert back to the first end portion 56. As a consequence, the chemical can flow uniformly in the bracket 50 so that the bracket 50 is more firmly fixed in place.

Furthermore, the reflecting portion 54 includes an upper end 54a which is provided on the erection wall 54b at a position higher than a centerline 20a of the injection hole 20 ( See FIG.7. ) . When the chemical is injected from the tool 4 through the injection hole 20 to hit the reflecting portion 54 having the upper end 54a higher than the centerline 20a of the injection hole 20, most of the chemical is distributed in the determined direction effectively as some of the chemical flow is diverted back to the first end portion 56 of the bracket 50 while some is diverted to the second end portion 58 through the beside area of the reflecting portion 54. Consequently, the chemical is distributed evenly in the bracket 50.

When the bracket 50 is viewed from above as illustrated in FIG.4 and FIG.6, the injection hole 20 and the reflecting portion 54 are positioned/ sandwiched between the plurality of walls 52, 52, as well as the plurality of walls 52, 52 are positioned in parallel when viewed from the top of the vehicle 1.

For this embodiment, two walls 52, 52 are spaced apart from and parallel to each other, as well as the injection hole 20 and the reflecting portion 54 are provided in between these two walls, in which the two walls 52, 52 are arranged to extend straight in the width direction from right to left sides. Alternatively, these two walls 52, 52 may be arranged obliquely to each other in forward or rearward directions.

The upper edge and the lower edge of each wall 52 are formed in a shape corresponding to that of the associated outer panel 10a of the vehicle body 10 and the wheelhouse panel 30, respectively. Optionally, as shown in FIG.7, the gaps between the upper edge of the wall 52 and the outer panel 10a of the vehicle body 10 and between the lower edge of the wall 52 and the wheelhouse panel 30 are allowed because the chemical is able to be filled in the gap in order to block the noise transmitted into the cabin.

With this arrangement, the bracket 50 is formed into the room structure by the arrangement of the plurality of walls 52, 52 which effectively blocks the chemical within a room of the bracket 50. As such, the chemical blocking in the room within the bracket 50 is sufficient and there is no need to fill the chemical in the entire vehicle gap 40, thereby, it is possible to reduce amount of the chemical which is injected to bracket 50. Also, since the structure 2 of the chemical injection includes the bracket 50 with the room structure, it is possible to improve the strength around the vehicle gap 40.

Moreover, since the injection hole 20, the reflecting portion 54 and the plurality of walls 52, 52 are aligned when viewed from the width direction of the vehicle 1 , it is effective to control chemical in the same direction.

Furthermore, the reflecting connection 60 is formed to connect to the plurality of walls 52, 52. The reflecting connection 60 connects the lower end of each wall 52.

Since the reflecting connection 60 is formed to connect the plurality of walls 52, 52, it is easily to form the reflecting connection 60 with the reflecting portion 54. Also, the reflecting connection 60 functions as the beam structure that holds between the plurality of walls 52, 52 firmly. Moreover, since the bracket 50 is firmly fixed in place resulting from the chemical which is distributed uniformly along the shape of the bracket 50, it is possible to inject the chemical with strong force.

The bracket 50 further includes an injection panel 62 having an opening portion 64. In FIG.7, the injection panel 62 is arranged to face the injection hole 20, and the opening portion 64 is aligned so as to face the injection hole 20. The opening portion 64 shares the axis concentrically with the injection hole 20. Preferably, the injection panel 62 is the first end portion 56 of the bracket 50. However, it is not limited that the injection panel 62 is the first end portion 56 of the bracket 50.

As shown in FIG. 5, The injection panel 62 is formed to extend towards the upper direction of the bracket 50 so as to become an approximately rectangular shape when viewed from the side of the bracket 50.

With this arrangement, it enables the chemical injection tool 4 to be inserted into the injection hole 20 of the vehicle body 10, the chemical injection tool 4 which passes through the injection hole 20 can pass through the opening portion 64 of the injection panel 62. Therefore, it is easy to set and control the tool 4 at a correct position where the chemical injects in the correct direction.

The injection panel 62 further includes an injection panel connection 66 which is formed to connect to the plurality of walls 52, 52. In particular, the injection panel connection 66 is formed to connect the plurality of walls 52, 52. It is easily to form the injection panel 62. Also, it functions as the beam structure that holds between the plurality of walls 52, 52 firmly. Moreover, since the bracket 50 is firmly fixed in place resulting from the chemical which is distributed uniformly along the shape of the bracket 50, it is possible to receive the tool 4 for the chemical injection firmly.

Furthermore, each of the plurality of walls 52, 52 includes a wall fixing portion 68 that is formed by extending from the lower end of the wall 52 to contact with the wheelhouse panel 30. The wall fixing portion 68 is formed in an approximately rectangular shape and corresponds to the plane of the wheelhouse panel 30 at the contacting area. Preferably, the wall fixing portion 68 is formed by folding the lower end of the wall 52 to contact with the wheelhouse panel 30.

Since each wall 52 includes the wall fixing portion 68 that is formed by extending from the lower end of the wall 52, the strength of the wall 52 improves. Moreover, since the wall fixing portion 68 is formed by folding a lower end of the wall 52 and connects with the wheelhouse panel 30, the plurality of walls 52, 52 stands more stably comparing with the plurality of walls 52, 52 fixed to the wheelhouse panel 30 without the wall fixing portion 68. Furthermore, as the wall fixing portion 68 is not extended to connect between the plurality of walls 52, 52, it makes the weight of the bracket 50 becomes lighter.

Furthermore, the bracket 50 includes at least a wall connection 70 which extends to connect between the walls 52, 52. Preferably, the wall connection 70 has a symmetrical shape. More preferably, the wall connection 70 has a substantially rectangular shape when viewed from above of the bracket 50.

With this arrangement, the strength of the wall 52 improves. The bracket 50 is firmly fixed in place resulting from the chemical which is distributed uniformly along the shape of the bracket 50, it is possible to inject the chemical with strong force. Moreover, in case that the wall connection 70 is formed to contact with the wheelhouse panel 30, a connecting area where the wall connection 70 contacts the wheelhouse panel 30 is larger than a connecting area where the wall 52 without the wall connection 70 contacts the wheelhouse panel 30. Therefore, it is possible that the strength of the bracket 50 and the wheelhouse panel 30 which correspond with the connected area improves.

The bracket 50 further includes a plurality of reinforcement portions 72 which are formed between the reflecting connection 60 and the wall 52, between the injection panel connection 66 and the wall 52, and between the at least one wall connection 70 and the wall 52. Preferably, the reinforcement portions 72 are pressed in a semicircular shape and formed to adjoin the wall 52. More preferably, the reinforcement portions 72 are pressed in a convex shape so as to project toward the upper end of the wall 52.

With this arrangement of the reinforcement portions 72, the strength of the wall 52 improves. Therefore, it is possible to inject the chemical with strong force. Moreover, in case that the reflecting connection 60, and the injection panel connection 66, and the at least one wall connection 70 are firmed to connect with the wheelhouse panel 30, connecting areas where the reflecting connection 60, and the injection panel connection 66, and the at least one wall connection 70 contact the wheelhouse panel 30 are stronger. Therefore, it is possible that the strength of the bracket 50 and the wheelhouse panel 30 which correspond with the connected area is improved.

Moreover, a center portion of each of the wall connection 70, the reflecting connection 60 and the injection panel connection 66 includes a ridge portion 84 which is formed in a ridge shape. For example, the narrow hilltop of the ridge portion 84 of at least one wall connection 70, the reflecting connection 60 and the injection panel connection 66 are formed towards the top direction of the vehicle 1. Since the center portion of each of the wall connection 70, the reflecting connection 60 and the injection panel connection 66 includes the ridge portion 84, the strength of the wall connection 70, the reflecting connection 60 and the injection panel connection 66 improves.

The wall 52 further includes a plurality of contacting portions extending from the wall 52 to adjoin the vehicle body 10 so as to increase the contacting area between the bracket 50 and the vehicle body 10. Specifically, the bracket 50 is provided with a first contacting portion 76 and a second contacting portion 78 which are formed to contact with the vehicle body 10 by extending from the wall 52 towards the horizontal direction (See FIG.5.) along the longitudinal direction of the vehicle 1. Moreover, the bracket 50 is provided with a third contacting portion 80 and a fourth contacting portion 82 which are formed to contact with the vehicle body 10 by extending from the wall 52 towards the top direction of the vehicle 1.

Next, the operation of the chemical injection structure 2 of this embodiment will be explained with reference to FIG.6.

First, the bracket 50 is installed to allow the reflecting portion 54 to face the injection hole 20 positioning at the vehicle body 10 and to allow the opening portion 64 on the injection panel 62 to adjoin the vehicle body 10, and concentrically shares the axis with the injection hole 20. The bracket 50 and the vehicle body 10 may be joined together in any of various manners, e.g. welding. Then, the wheelhouse panel 30 is attached to form the enclosed body space.

Secondly, the chemical injection tool 4 is inserted into the injection hole 20 and the opening portion 64. The chemical injection tool 4 can be inserted into the injection hole 20 and the opening portion 64 because the opening porting 64 shares the axis concentrically with the injection hole 20.

Thirdly, the chemical is injected from the tool 4 into the bracket 50. Specifically, the flow of the chemical is directed to hit the reflecting portion 54 ( See Arrow A in FIG.6. ) . With the arrangement of the reflecting portion 54, the chemical flow is diverted to two regions, including diverting back to the first end portion 56 of the bracket 50 (See Arrow B.) and diverting to the second end portion 58 of the bracket 50 (See Arrow C) by passing through the open beside areas of the reflecting portion 54.

Finally, the chemical flows to fill in the gap between the bracket 50 and the vehicle body 10 and between the bracket 50 and the wheelhouse panel 30. As such, it is possible to block the noise passing through the vehicle gap 40 and into the cabin in order to reduce sound transmission.

Therefore, the flow direction of the chemical can be controlled. The chemical is injected through the injection hole 20 and then flows to hit the reflecting portion 54, resulting in diverting the chemical flow direction so that the chemical is distributed in the predetermined direction. Moreover, the bracket 50 can be manufactured easily as its structure is simplified, enabling to reduce the manufacturing cost and time.

Next, the sound insulation due to the chemical injection structure 2 for the vehicle 1 will be explained.

Firstly, the noise, especially road noise is generated by vehicle’ s tires moving on the surface of the road.

Next, the sound wave reaches the bracket 50 which filled with the chemical and then most of the sound wave is reflected back within the smaller space of the vehicle gap 40. Thus, it is very difficult for the sound wave to continuously and resonantly propagate in the vehicle gap 40 to transmit to the cabin, thereby achieving the purpose of sound insulation.

Although specific embodiments of the invention have been disclosed and described as well as illustrated in the companying drawings, it is simply for the purpose of better understanding of the principle of the present invention and it is not as a limitation of the scope and spirit of the teaching of the present invention. Adaption and modification to various structures such as design or material of the invention, mounting mechanism of various parts and elements or embodiments are possible and apparent to a skilled person without departing from the scope of the present invention which is to be determined by the claims.

List of reference:

1 vehicle

2 chemical injection structure

4 chemical injection tool

10 vehicle body

10a outer panel of vehicle body

20 injection hole

20a centerline of injection hole

30 wheelhouse panel

40 vehicle gap

50 bracket

52 wall

54 reflecting portion

54a upper end of reflecting portion

54b erection wall

56 first end portion 58 second end portion

60 reflecting connection

62 injection panel

64 opening portion 66 injection panel connection

68 wall fixing portion

70 wall connection

72 reinforcement portion

76 first contacting portion 78 second contacting portion

80 third contacting portion

82 fourth contacting portion

84 ridge portion