Abstract:
In a joining structure, a protruding portion on the side of a first component is a hollow body that prevents bringing about sinking, deforming, and cracking of the side surface of the first component part, even in the event that the protruding portion is enlarged in order to increase strength for connecting the first component part and a second component part. In addition, the connecting groove on the side of the second component part is also defined by a hollow body that includes a pair of supporting ribs and a supporting plate bridging the pair of supporting ribs. Consequently, the hollow body can prevent defects of sinking, deforming, and cracking in the side surface of the second component part, even in the event that the supporting ribs and the supporting plate are increased in thickness in order to enhance the rigidity of the coupling arrangement between the first and second component parts.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a joining structure for fitting parts or articles together, in particular, for use in the process of assembling component parts, such as interior parts of vehicles. 
   2. Description of the Related Art 
   In the production line of vehicles, it is repeatedly performed by workers to attach various kinds of interior parts such as console boxes and door linings to vehicle bodies. Those parts have to be infallibly attached in the predetermined positions. In addition, it is desirable to simplify and facilitate the work of attachment of the parts and to shorten the amount of time required for attaching the parts, especially when those parts are attached to mass-produced cars. 
   Japanese Patent Public Disclosure P2000-118318A discloses a structure for mounting a plate member on linings of a vehicle and a decorative component of a vehicle having the same structure. The plate mounting structure comprises a hook of a generally T-shaped cross section which is attached to a component part such as a door liner pad, a pair of stick-like guides formed on the hook or a substrate plate coalesced into the hook, and a hole formed in a member such as a door trim board. The hook of a T-shaped cross section has a head portion extending horizontally and a leg portion extending vertically. In addition, the pair of stick-like guides extend in parallel with the head portion of the hook. On the door trim board, a pair of protruding portions are formed beside the hole and a recess or slit is formed between the protruding portions to receive the leg portion of the hook therein. When mounting a decorative component such as the door liner pad on the door trim board, the head portion of the hook is inserted into the hole of the door trim board and then the hook is slid toward the protruding portions in order that the leg portion of the hook enter the recess or slit between the protruding portions. Thereby, the head portion of the hook is brought into contact with the upper surfaces of the protruding portions, while the pair of stick-like guides are brought into contact with the lower surfaces of the protruding portions. As a result, the protruding portions are wedged between the head portion and the stick-like guides so that the door liner pad of a decorative component is mounted on the door trim board of a vehicle. 
   The plate mounting structure disclosed in P2000-118318A has a structure that the head portion of the hook and the pair of protruding portions are interlocked to fix the door liner pad onto the door trim board. In order to enhance rigidity of the coupling arrangement between the door liner pad and the door trim board, it is, therefore, necessary to increase the thickness of the junction between the head and leg portions of the hook. In the event that the hook is molded from a synthetic resin and the thickness of the junction is increased, however, there is the possibility that a recess or so-called sink, a deformation or a crack is produced in the upper surface of the head portion when the junction between the head and leg portions are cooled down. If the sink, deformation and/or crack is formed in the upper surface of the head portion, the head portion has to be covered by another part to prevent the sink, deformation and crack from being exposed to the cabin of a vehicle. The sink, deformation and/or crack may be also formed in one side of the substrate plate, when the hook and the substrate plate was integrally molded from a synthetic resin and the leg portion of the hook coalesced into the other side of the substrate plate. In this case, it is also necessary to cover the defects on the side surface of the substrate plate by another means when the defected surface of the substrate plate is exposed to the interior of a cabin. 
   In addition, the plate mounting structure disclosed in Japanese Patent Public Disclosure P2000-118318A has a hole put through a member such as a door trim board, into which the head portion of the hook is inserted. The hole is left open after the head portion of the hook and the pair of protruding portions were interlocked to fix the door liner pad onto the door trim board. Therefore, the plate mounting structure cannot be used in the state that the member having the hole appears on the outside. 
   Furthermore, in order to fix the door liner pad onto the door trim board, the plate mounting structure mentioned above requires the following two steps of: inserting the head portion of the hook into the hole; and sliding the hook toward the protruding portions. The direction of inserting the head portion is at a right angle to the direction of sliding the hook. Consequently, the two steps have to be carried out as a discontinuous action. Therefore, the mounting work required for the plate mounting structure is not always efficient. 
   SUMMARY OF THE INVENTION 
   The objective of the present invention is to provide a joining structure of component parts that facilitates the coupling of component parts and simplifies the connecting activities of parts. 
   Another objective of the present invention is to provide a joining structure of component parts that can fix a component part onto another part quickly. 
   Further objective of the present invention is to provide a joining structure of component parts that generates a sufficient strength of connecting component parts. 
   Further objective of the present invention is to provide a joining structure of component parts, wherein the connected parts joined by the joining structure can be used as a product or a part of a product without any further processing of the product. 
   In order to achieve the aforementioned objects, a joining structure as a first aspect of the present invention comprises: 
   a first component part having a hollow protruding portion projecting from the side surface of said first component part, a flange portion projecting from the outer periphery of said hollow protruding portion with leaving a space from the side of said first component part, and an abutting surface formed on said flange portion to be opposed to the side surface of said first component part; 
   a second component part having a connecting groove for receiving said flange portion therein, said connecting groove extending along the side surface of said second component part and comprising a side slot for inserting said flange portion into said connecting groove, an upper slot for receiving said hollow protruding portion therein, and a bearing surface to be engaged with said abutting surface; and 
   one or more strut portions formed on said first and/or second component parts, wherein said strut portions are compressed between said first and second component parts when said flange portion is inserted into said connecting groove, and whereby said abutting surface and said bearing surface are clamped together by the force exerted by said strut portions. 
   A joining structure as a second aspect of the present invention comprises: 
   a first component part having a hollow protruding portion projecting from the side surface of said first component part, a flange portion projecting from the outer periphery of said hollow protruding portion with leaving a space from the side of said first component part, an abutting surface formed on said flange portion to be opposed to the side surface of said first component part, and one or more latch portions formed on the side edges of said flange portion; 
   a second component part having a connecting groove ( 23 ) for receiving said flange portion therein, said connecting groove extending along the side surface of said second component part and comprising a side slot for inserting said flange portion into said connecting groove, an upper slot for receiving said hollow protruding portion therein, a bearing surface to be engaged with said abutting surface, and one or more intermediate slots for receiving said latch portions; and 
   one or more strut portions formed on said first and/or second component parts, wherein said strut portions are compressed between said first and second component parts when said flange portion is inserted into said connecting groove, and whereby said abutting surface and said bearing surface are clamped together by the force exerted by said strut portions. 
   In the specification, the term of “hollow” means that the interior of an item, part or member is not filled with a material which makes up the item, and it does not matter whether an interior space of the item is closed or not. Similarly, the terms of “a hollow body” used in the specification means an item whose interior is not filled with a material which makes up the item, and it does not matter whether an interior space of the item is closed or not. 
   In the joining structure of the present invention, the protruding portion formed on the side of a first component part takes the form of a hollow body that prevents bringing about sinking, deforming and cracking of the side surface of the first component part, even in the event that the protruding portion is enlarged in order to increase the strength for connecting the first component part and a second component part. In addition, the connecting groove formed on the side of the second component part is also defined by a hollow body that comprises a pair of supporting ribs and a supporting plate bridging the pair of supporting ribs. Consequently, the hollow body can prevent generating the defects of sinking, deforming and cracking in the side surface of the second component part, even in the event that the supporting ribs and the supporting plate are increased in thickness in order to enhance the rigidity of the coupling arrangement between the first and second component parts. 
   Furthermore, no opening exists on the product surfaces of the first and second component parts to be joined together. Therefore, the joined parts can be used as a product or a part of a product without any further processing of the product. 
   In addition, the first and second component parts can be joined by inserting a flange portion of the first component part into the connecting groove of the second component part only in one direction. Therefore, the parts can be joined quickly and easily. 
   These and other advantages or effectiveness of the present invention will be defined from the detailed description of the present invention, which is made with reference to the accompanied drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is an exploded perspective view of an automotive console assembly having a joining structure of a type in which joining is effected in a horizontal direction; 
       FIG. 1B  is an exploded perspective view of an automotive console assembly having a joining structure of a type in which joining is effected in a vertical direction; 
       FIG. 2  is a fragmentary, perspective view showing left and right side panels of the console assembly shown in  FIG. 1A ; 
       FIG. 3  is a fragmentary, perspective view of a console box of the console assembly shown in  FIG. 1A ; 
       FIG. 4A  is a plan view of the joining structure shown in  FIGS. 2 and 3 ; 
       FIG. 4B  is a sectional view taken along the line A-A in  FIG. 3 ; 
       FIG. 4C  is a sectional view taken along the line B-B in  FIG. 4A ; 
       FIG. 5  is a fragmentary, perspective view of a console box shown as a second embodiment of the present invention; 
       FIG. 6  is a sectional view taken along the line C-C in  FIG. 5 ; 
       FIG. 7  is a fragmentary, perspective view of left and right side panels shown as a second embodiment of the present invention; 
       FIG. 8  is a fragmentary, perspective view of left and right side panels shown as a third embodiment of the present invention; 
       FIG. 9  is a fragmentary, perspective view of a console box shown as a third embodiment of the present invention; 
       FIG. 10  is a plan view of the joining structure shown in  FIGS. 8 and 9 ; and 
       FIG. 11  is a sectional view taken along the line D-D in  FIG. 9 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Hereinafter, embodiments of the invention will be described by taking as an example a console assembly, which is to be disposed between a driver&#39;s seat and a front passenger&#39;s seat of a motor vehicle. 
   Embodiment 1 
     FIGS. 1 to 4  shows a first embodiment of the present invention. As is shown in  FIG. 1A , a console assembly  1  is made up by connecting a right side panel  3  and a left side panel  4  to a console box  2  which is made to open at a top thereof. The box  2 , the right side panel  3  and the left side panel  4  are integrally molded from a synthetic resin material, respectively. Four supporting portions  5  are formed integrally on each of left and right sides of the box  2 . Four flange portions  6  are formed integrally on each of the left and right side panels  3 ,  4 . These flange portions  6  are positioned in such a manner as to correspond to the supporting portions  5  on the box  2 . 
     FIG. 1B  shows a console assembly which is similar to that shown in  FIG. 1A , and in  FIG. 1B , constituent components given like reference numerals to those in  FIG. 1A  are constituent components having like designations. However, the console assembly  1  illustrated in  FIG. 1B  differs from that shown in  FIG. 1A  in that supporting portions  5  and flange portions  6  thereof are formed in a different direction. The supporting portion  5  in  FIG. 1B  is made into a form which results by rotating the supporting portion  5  in  FIG. 1A through 90  degrees in a clockwise direction, and the flange portion  6  illustrated in  FIG. 1B  is made into a form which results by rotating the locking portion  6  in  FIG. 1A  through 90 degrees in a counterclockwise direction. 
   Due to those differences, the way of assembling the side panels to the box becomes different between the console assemblies shown in  FIGS. 1A and 1B . Namely, in the console assembly  1  shown in  FIG. 1A , the flange portions  6  are brought into engagement with the corresponding supporting portions  5  by moving the left and right side panels  3  and  4  in a longitudinal direction of each side panel relative to the box  2 , whereas in the console assembly  1  shown in  FIG. 1B , the supporting portions  5  and the flange portions  6  are brought into engagement with each other by moving the left and right side panels  3  and  4  in a downward direction in the figure relative to the box  2 . The supporting portions  5  and the flange portions  6  in  FIG. 1A  and the supporting portions  5  and the flange portions  6  in  FIG. 1B  have the same configurations. 
   In both the console assemblies  1  in  FIGS. 1A and 1B , interior surfaces RS 2  of the box  2  and exterior surfaces RS 1 , of the left and right side panels  3 ,  4  constitute product surfaces. The exterior surfaces RS 1  of the left and right side panels  3 ,  4  mean surfaces opposite to surfaces thereof where the flange portions  6  are formed. 
   As is shown in  FIG. 1A  or  FIG. 1B , the four flange portions  6  are formed integrally on the rear surfaces of the left and right side panels  3 ,  4 , respectively. In addition, the eight supporting portions  5  are formed on the exterior surfaces of the box  2  in such a manner as to correspond to the flange portions  6 , respectively. As is shown in  FIG. 2 , the portions on the left and right side panels  3 ,  4  where the flange portions  6  are formed are made to constitute connecting portions  7 , and as is shown in  FIG. 3 , the portions on the box  2  where the supporting portions  5  are formed are made to constitute connecting portions  8 . The numbers of connecting portions  7  and  8  are arbitrary. Hereinafter, embodiments of the present invention will be described by taking as examples one of the connecting portions  7  formed on the left side panel  4  shown in  FIG. 1A  and one of the connecting portions  8  formed on the box  2  shown in  FIG. 3 . Including the modified example shown in  FIG. 1B  the configurations of the other connecting portions  7  and  8  are the same as the configurations of the connecting portions  7  and  8  which will be described below. 
   As is shown in  FIG. 2 , a hollow protruding portion  9  is formed integrally on the connecting portion  7  on the left side panel  4 , and a plate-shaped locking portion  6  is formed integrally on an end face of the protruding portion  9  in such a manner as to be spaced apart a certain distance from the connecting portion  7 . An opening  10  is formed in a central portion of the flange portion  6 , and the opening  10  communicates with an interior space  11  of the protruding portion  9 . As is shown in  FIG. 4A , the hollow protruding portion  9  is formed substantially into the shape of U, which is the twenty-first letter of the alphabet in cross section, and a distal end portion thereof is formed into a smooth curved surface, whereas a rear end portion thereof is closed by a bend portion  13  of the plate-shaped locking portion  6  which is bent downwards. An abutting surface  14  is formed on a surface of surfaces of the plate-shaped locking portion  6  which faces a surface of the connecting portion  7 . As is shown in  FIGS. 2 and 4 , the abutting surface  14  is formed on the perimeter of the protruding portion  9 . In addition, the plate-shaped flange portion  6  has a distal bent portion  15  which is bent towards the box  2 , and the bent portion  15  provides a guide surface for connecting the flange portion  6  to the supporting portion  5 . 
     FIG. 3  shows a connecting portion  8  of the box  2  which is brought into engagement with the flange portion  6  and the protruding portion  9  of the connecting portion  7  on the left side panel  4 . The connecting portion  8  is positioned where four reinforcement ribs  16 ,  17 ,  18 ,  19  intersect each other which are formed on an exterior surface of the box  2  in such a manner as to protrude therefrom. The supporting portion  5  formed at the connecting portion  8  has a pair of supporting ribs  20 ,  21  which are formed integrally on the reinforcement ribs  16 ,  17 , respectively, and a supporting plate  22  is molded integrally between the supporting ribs  20 ,  21  in such a state that the supporting plate  22  bridges the supporting ribs  20 ,  21 . A connecting groove  23  is formed between the supporting plate  22  and a surface of the connecting portion  8  of the box  2 , and the connecting groove  23  extends between the supporting ribs  20 ,  21 . An opening  24 , into which the flange portion  6  is inserted, is formed at one end of the connecting groove  23 , and an opening  25 , from which the distal bent portion  15  of the flange portion  6  protrudes, is formed at the other end of the connecting groove  23 . 
   An upper slot  26  is formed in the supporting plate  22  in such a manner as to receive therein the protruding portion  9  formed on the connecting portion  7  on the left side panel  4 . The upper slot  26  is made to open to a side slot  24  on the side of the connecting groove  23  and extends along the connecting groove  23  in a direction in which the protruding portion  9  enters. As is shown in  FIG. 4A , a step portion  27  is formed at an intermediate portion along the length of the upper slot  26  in such a manner that the step portion  27  so formed is brought into engagement with a shoulder portion  28  of the protruding portion  9  which has entered the upper slot  26  so as to prevent the dislodgement of the protruding portion  9  from the upper slot  26 . Since the supporting ribs  20 ,  21  are formed integrally on the reinforcement ribs  16 ,  17 , respectively, they each have a high rigidity, but since the protruding portion  9  is the hollow body having the opening  10 , the protruding portion  9  can deform when entering the upper slot  26 . 
   A bearing surface  29  is formed on a side of the supporting plate  22  which faces the connecting groove  23 . The bearing surface  29  is situated on the perimeter of the upper slot  26 . The bearing surface  29  is formed in such a position that the bearing surface  29  is allowed to be brought into engagement with the abutting surface  14  of the plate-shaped flange portion  6  when the connecting portion  7  on the left side panel  4  is connected to the connecting portion  8  on the box  2 . 
   Extension ribs  30 ,  31  are formed at distal end portions of the supporting ribs  20 ,  21 , respectively, in such a manner as to protrude therefrom. The extension ribs  30 ,  31  are brought into press contact with the connecting portion  7  or in the vicinity thereof on the left side panel  4  when the connecting portion  7  of the left side panel  4  is connected to the connecting portion  8  of the box  2 , so as to function as a strut for interlocking the abutting surface  14  of the plate-shaped flange portion  6  to the bearing surface  29  of the supporting plate  22  under pressure. In addition, as is shown in  FIG. 4C , the extension ribs  30 ,  31  each have a curved surface  32  which is inclined moderately towards the side slot  24  in the connecting groove  23 . The curved surface  32  constitutes a guide surface when the plate-shaped flange portion  6  is inserted into the connecting groove  23 . 
   In the embodiment shown in  FIG. 1A , in order to connect the left side panel  4  to the box  2 , the plate-shaped flange portion  6  formed at the connecting portion  7  on the left side panel  4  as shown in  FIG. 2  is inserted into the connecting groove  23  formed at the connecting portion  8  on the box  2  shown in  FIG. 3 , and at the same time, the hollow protruding portion shown in  FIG. 2  is pushed into a deepest portion of the upper slot  26  shown in  FIG. 3 , whereby as is shown in  FIG. 4B , since the extension ribs  30 ,  31  of the box  2  are brought into press contact with the vicinity of the connecting portion  7  on the left side panel  4 , so as to attempt to forcibly open a space between the left side panel  4  and the box  2 , the abutting surface  14  of the plate-shaped flange portion  6  and the bearing surface  29  of the supporting plate  22  are interlocked with each other under pressure, whereby the position and posture of the panel  4  relative to the box  2  are maintained. In addition, as this occurs, the shoulder portion  28  of the protruding portion  9  is brought into engagement with the step portion  27  of the upper slot  26 , so as to prevent the disengagement of the connection between the panel  4  and the box  2 . 
   In addition, the connecting portions  7  and  8 , which are provided four each, are connected to each other at the same time that the left side panel  4  is connected to the box  2 . Namely, in the embodiment shown in  FIG. 1A , the connection of the panel  4  and the box  2  is established only by performing an operation in which the panel  4  is caused to move in its longitudinal direction so that the four connecting portions  7  on the panel  4  are brought into engagement with the four connecting portions  8  on the box  2  simultaneously. A connection of the right side panel  3  to the box  2  will be effected in a similar manner. In addition, in the modified example shown in  FIG. 1B , the left and right side panels  3 ,  4  are connected to the box  2 , respectively, through operations in which the left and right side panels  3 ,  4  are caused to move downwards relative to the box  2 . In this way, the connection of the left and right side panels  3 ,  4  to the box  2  is established, whereby the console assembly  1  is assembled completely. 
   Interior surfaces RS 2  of the box  2  and exterior surfaces RS 1  of the left and right side panels  3 ,  4  of the console assembly  1  can constitute product surfaces of the console assembly  1  as they are. Namely, the supporting portion  5  formed integrally on the connecting portion  8  of the box  2  constitutes a hollow body which is made to open to the outside by virtue of the existence of the connecting groove  23  having the side slot  24 . In addition, the protruding portion  9  formed integrally on the connecting portion  7  of each of the left and right side panels  3 ,  4  constitutes a hollow body which is made to open to the outside by virtue of the existence of the interior space  11  having the opening  10 . Due to this, even when the box  2  and the panels  3 ,  4  are formed from synthetic resin, an internal stress is made difficult to be produced when the synthetic resin molded bodies are cooled which stress would otherwise be produced at the portions where the hollow bodies are formed in association with the shrinkage of the synthetic resin material. Consequently, it is possible to prevent the generation of defects such as sink mark, deformation, cracking and the like on the interior surfaces RS 2  of the box  2  and the exterior surfaces RS 1  of the left and right side panels  3 ,  4 . It is noted that an armrest which can be opened and closed (not shown) is mounted over an opening of the box  2 . 
   Embodiment 2 
     FIGS. 5 to 7  show a second embodiment of the invention. In  FIGS. 5 to 7 , same reference numerals to those used in  FIGS. 1 to 4  denote constituent components having the same designations as those described in  FIGS. 1 to 4 . The features of this embodiment resides in a configuration in which in place of the extension ribs  30 ,  31  in the first embodiment, a ridge portion  33  is formed in such a manner as to surround an opening  10  in a plate-shaped flange portion  6  formed at a connecting portion  7  of each of left and right side panels  3 ,  4 , and distal end portions of the ridge portion  33  are made to continuously contact a rear end bent portion  13 A of the flange portion  6 . Since the rear end bent portion  13 A is connected to the ridge portion  33 , the rear end bent portion  13 A has a portion which protrudes further downwards from an opening  10  side surface of the flange portion  6  than the rear end bent portion  13  of the first embodiment. In addition, a supporting portion  5  formed at a connecting portion  8  of a box  2  has a supporting plate  22  which is formed integrally with reinforcement ribs  16 ,  17  in such a state that the supporting plate  22  bridges the reinforcement ribs  16 ,  17 . A connecting groove  23  extends between the supporting plate  22  and a surface of the connecting portion  8 . The other configurations are the same as those of the first embodiment. 
   As is shown in  FIG. 6 , when the plate-shaped flange portion  6  is inserted into the connecting groove  23 , the ridge portion  33  is brought into press contact with a surface of the connecting portion of the box  2  so as to function as a strut, and an abutting surface  14  of the plate-shaped flange portion  6  and a bearing surface  29  of the supporting plate  22  are bonded to each other under pressure, whereby the position and posture of the panel  4  relative to the box  2  are maintained, so that the connecting strength between the box  2  and the left and right side panels  3 ,  4  can be increased. In addition, since no portion exists at the connecting portion  8  of the box  2  which protrudes further than the reinforcement ribs  16 ,  17 , the storability of the box  2  can also be enhanced. 
   Embodiment 3 
     FIGS. 8 to 10  show a third embodiment. In  FIGS. 8 to 10 , same reference numerals to those used in  FIGS. 1 to 4  denote constituent components having the same designations. The features of this embodiment resides in a configuration in which in place of the shoulder portion  28  of the protruding portion  9  and the step portion  27  of the upper slot  26 , a pair of flange projections  6 A,  6 B are formed on a plate-shaped flange portion  6  and intermediate slots  30 A,  31 A are formed in supporting ribs  20 ,  21 , respectively, in such a manner as to open to edge portions of extension ribs  30 ,  31 , so that, when left and right side panels  3 ,  4  are connected to a box  2 , the flange projections  6 A,  6 B are brought into engagement with the intermediate slots  30 A,  31 A, respectively, whereby connecting portions  7  of the left and right side panels  3 ,  4  can be prevented from being dislodged from connecting portions  8  of the box  2  in an ensured fashion. The other configurations are similar to those of the first embodiment. 
   It is noted that, while in the first to third embodiments, the protruding portion  9  is formed substantially into the shape of U, which is the twenty-first letter of the alphabet, in cross section, a projecting portion formed into the shape of an arbitrary alphabet letter, for example, H, M and the like, in cross section can be used in the connecting construction of the invention. 
   In addition, while in the first to third embodiments, the hollow protruding portions and flange portions are formed on the left and right side panels and the supporting portions are formed on the box, the supporting portions may be formed on the left and right side panels and the hollow protruding portions and flange portions may be formed on the box. 
   Furthermore, the interlocking structure of the third embodiment of the invention shown in  FIGS. 8 to 10  which are made up of the flange projections  6 A,  6 B and the intermediate slots  30 A,  31 A can be formed on the joining structure of the second embodiment of the invention shown in  FIGS. 5 to 7 . 
   The present invention realizes a joining structure of component parts producing the aforementioned features and advantages, without diminishing moldability of the products to be integrally molded from synthetic resin. 
   It is noted that the joining structure of the present invention can be used not only when joining automotive interior parts but also when connecting other items to each other.