Vehicle sun visor

A vehicle sun visor includes a sun visor body, an arm including a cylindrical end portion provided with contact parts of a pair of conductors and rotatably holding the sun visor body, a mounting bracket configured to mount the arm to a vehicle, and a connector having a pair of terminals each including a contact portion configured to contact each contact part. The mounting bracket includes an arm-supporting portion supporting the cylindrical end portion. The contact parts are a pair of arcuate-plate-shaped contact parts. The pair of arcuate-plate-shaped contact parts is provided at a predetermined interval on an outer peripheral surface of the cylindrical end portion. The housing of the connector further includes a lubricating oil reservoir being disposed at a position facing to at least one arcuate-plate-shaped contact part and configured to store lubricating oil to be supplied to the at least one arcuate-plate-shaped contact part.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority of Japanese Patent Application No. 2017-163005, filed on Aug. 28, 2017, the entire content of which are incorporated herein by reference.

BACKGROUND

Technical Field

The present invention relates to a vehicle sun visor with illumination arranged in the vicinity of an upper end of a front window of a front seat of a vehicle.

Related Art

A vehicle sun visor of this type is disclosed in JP 2011-230559 A. As shown inFIG. 11, the vehicle sun visor1includes a non-conductive support shaft (arm)2for rotatably holding a sun visor body (not shown), a mounting bracket5for mounting the support shaft2to a ceiling of a vehicle cabin (not shown), and a connector7detachably assembled to the mounting bracket5and having a pair of terminals8and8for supplying electric power.

A pair of conductors3and3extending in parallel is arranged inside the support shaft2. Each columnar conductor end portion3aserving as the contact parts of a pair of conductors3and3is provided on the closed upper surface of an end portion2atoward the mounting bracket5so as to protrude outward. The pair of columnar conductor end portions3aand3ais spaced apart from each other, having a space, via a non-conductive intervening portion2bprotruding to the center of the upper surface of the end portion2aof the support shaft2.

The end portion2aof the support shaft2is rotatably supported by a cylindrical support protrusion portion5aof the mounting bracket5, and a housing7aof the connector7is assembled to a mounting recess portion5bof the mounting bracket5.

When the support shaft2is rotated to a first position, the pair of columnar conductor end portions3aand3aprotruding outward from the end portion2acontacts each spring portion8aof the pair of terminals8and8for supplying electric power to be brought into an energized (ON) state, whereby a lighting preparation state of the illumination lamp of the sun visor body is formed.

When the support shaft2is rotated to the second position, the pair of columnar conductor end portions3aand3aprotruding outward from the end portion2ais away from each spring portion8aof the pair of terminals8and8for supplying electric power to be in a non-conducting (OFF) state.

SUMMARY

In the conventional vehicle sun visor1, by pivoting the support shaft2, the columnar conductor end portion3aserving as a contact part protruding outward from the end portion2aof the support shaft2and the plate-shaped spring portion8aserving as a contact part of the terminal8assembled to the housing7aof the connector7slide to each other and wear. Therefore, grease is applied to the spring portion8aof the terminal8in order to protect the contact part of the conductor end portion3aand the spring portion8a. However, as the grease is gradually removed by the sliding of the contact parts due to repeated rotation of the support shaft2, when the grease disappears, contact wear occurs and the resistance between the contacts rises, and the contact reliability may be lowered.

The present invention is made to solve this problem, and it is an object of the present invention to provide a vehicle sun visor capable of constantly supplying lubricating oil to prevent contact wear of a contact part of a conductor of an arm and a contact part of a terminal.

A vehicle sun visor according to an aspect of the present invention includes a sun visor body including an electrical component, a non-conductive arm including a cylindrical end portion provided with contact parts of a pair of conductors and rotatably holding the sun visor body, a mounting bracket configured to mount the non-conductive arm to a vehicle, and a connector detachably attached to the mounting bracket and having a pair of terminals configured to supply electric power, each terminal having a contact portion configured to contact each contact part of the contact parts of the pair of conductors. The mounting bracket includes an arm-supporting portion supporting the cylindrical end portion of the non-conductive arm to be rotatable. The contact parts of the pair of conductors are a pair of arcuate-plate-shaped contact parts each formed in an arcuate plate shape. The pair of arcuate-plate-shaped contact parts is provided at a predetermined interval on an outer peripheral surface of the cylindrical end portion, the outer peripheral surface being exposed outside of the arm-supporting portion. The housing of the connector further includes a lubricating oil reservoir being disposed at a position facing to at least one arcuate-plate-shaped contact part of the pair of arcuate-plate-shaped contact parts of the housing of the connector and configured to store lubricating oil to be supplied to the at least one arcuate-plate-shaped contact part.

Each terminal of the pair of terminals may include a spring portion provided with the contact portion. The housing may have a protruding wall provided at a position corresponding to each spring portion and covering each spring portion. The protruding wall may include the lubricating oil reservoir.

The cylindrical end portion exposed outside of the arm-supporting portion may include a small-diameter cylindrical end portion arranged on an upper side of the cylindrical end portion and a large-diameter cylindrical end portion arranged on a lower side of the cylindrical end portion. Further, cutouts may be provided at alternate positions of the small-diameter cylindrical end portion and the large-diameter cylindrical end portion. A first arcuate-plate-shaped contact part of the pair of arcuate-plate-shaped contact parts may be disposed on an outer peripheral surface of the small-diameter cylindrical end portion, and a second arcuate-plate-shaped contact part of the pair of arcuate-plate-shaped contact parts may be disposed on an outer peripheral surface of the large-diameter cylindrical end portion. The lubricating oil reservoir may be provided at a position facing the second arcuate-plate-shaped contact part of the protruding wall and may be configured to store the lubricating oil to be supplied to the second arcuate-plate-shaped contact part.

The pair of arcuate-plate-shaped contact parts may be each provided via a gap at the same height in the extending direction of the non-conductive arms on an outer peripheral surface of the cylindrical end portion which is exposed on the outside of the arm-supporting portion. The lubricating oil reservoir may be provided at a position facing the pair of arcuate-plate-shaped contact parts of the protruding wall and may be configured to store the lubricating oil to be supplied to the pair of arcuate-plate-shaped contact parts.

A vehicle sun visor according to the aspect of the present invention is capable of always suppling lubricating oil from the lubricating oil reservoir provided in the housing of the connector to an arcuate-plate-shaped contact part provided on the outer peripheral surface of the cylindrical end portion of the arm exposed outside of the arm-supporting portion even when the arm is repeatedly rotated with respect to the arm-supporting portion of the mounting bracket, and reliably preventing contact wear due to sliding of the contact part of the conductor of the arm and the contact part of the terminal.

DETAILED DESCRIPTION

Description will be hereinbelow provided for embodiments of the present invention by referring to the drawings. It should be noted that the same or similar parts and components throughout the drawings will be denoted by the same or similar reference signs, and that descriptions for such parts and components will be omitted or simplified. In addition, it should be noted that the drawings are schematic and therefore different from the actual ones.

FIG. 1is a perspective view of a vehicle sun visor according to one embodiment of a first embodiment,FIG. 2is a side view showing a state in which the vehicle sun visor is stored toward a ceiling of a cabin,FIG. 3is a perspective view showing a state before the cylindrical-end portion of an arm is press-fitted to a mounting bracket of the vehicle sun visor,FIG. 4is a perspective view showing a state before a pair of terminals is inserted into a housing of a connector of the vehicle sun visor,FIG. 5is a perspective view showing a state before the connector is assembled to the mounting bracket to which the arm is attached,FIG. 6is a side view showing a state in which the connector is being assembled to the mounting bracket,FIG. 7is a perspective view showing a state in which the connector has been assembled to the mounting bracket, andFIG. 8is a perspective view showing a principal part of the housing of the connector in cross section.

As shown inFIGS. 1 to 4, the vehicle sun visor10includes a sun visor body11having a vanity mirror (makeup mirror)12and an illumination lamp (electrical equipment)13, a non-conductive arm20rotatably holding the sun visor body11and provided with each contact part29A and29B of a pair of conductors28and28at a cylindrical-end portion21, a mounting bracket30for mounting the arm20to a roof trim (vehicle)60, and a connector40detachably attached to the mounting bracket30and having a pair of terminals50and50for supplying electric power wherein the terminal has contact portion53being in contact with each contact part29A and29B of the pair of conductors28and28.

As shown inFIGS. 3, 5, and 7, the arm20is formed in a cylindrical shape with a synthetic resin. The arm20is formed so that the cylindrical-end portion21whose upper surface21ais closed is inclined at a predetermined angle with respect to an arm body20A. The pair of conductors28and28extending in parallel is routed inside the arm20. The contact parts29A and29B of the arm20of the pair of conductors28and28are formed in an arcuate plate shape wherein the contact parts29A and29B are exposed toward the cylindrical-end portion21of the arm20and positioned at the cylindrical-end portion21(hereinafter referred to as “a pair of arcuate-plate-shaped contact parts29A and29B”). Further, a small-diameter cylindrical-end portion22is provided on the upper side of a portion of the cylindrical-end portion21of the arm20wherein the portion is exposed outside the arm-supporting portion31of the mounting bracket30described below, and a large-diameter cylindrical-end portion23is provided on the lower side of the portion. Cutouts22band23bare provided at alternate positions of the small-diameter cylindrical-end portion22and the large-diameter cylindrical-end portion23, that is, the position of the cutout22bon the small-diameter cylindrical-end portion22and the position of the cutout23bon the large-diameter cylindrical-end portion23are opposed to each other in the diameter direction. First arcuate-plate-shaped contact part29A, which is one of the pair of arcuate-plate-shaped contact parts29A and29B, is arranged in an annular recessed groove portion22cformed on the outer peripheral surface22aof the small-diameter cylindrical-end portion22. Second arcuate-plate-shaped contact part29B, the other of the pair of arcuate-plate-shaped contact parts29A and29B, is arranged in an annular recessed groove portion23cformed on the outer peripheral surface23aof the large-diameter cylindrical-end portion23. A pair of cutouts22band23bpositioned alternately between the pair of arcuate-plate-shaped contact parts29A and29B is a non-contact area between the pair of arcuate-plate-shaped contact parts29A and29B and each contact portion53of the pair of terminals50and50.

Further, as shown inFIGS. 3 and 5, an annular flange portion24to be engaged with an engaging protrusion48(described later) for assembling the connector40integrally protrudes and is formed on the lower side of the large-diameter cylindrical-end portion23. Further, the annular recessed engagement groove25is integrally formed on the lower side of the annular flange portion24. A cutout24afor guiding the engaging protrusion48of the connector40is formed in the annular flange portion24. An annular flange portion26having a diameter larger than that of the annular flange portion24integrally protrudes and is formed on the lower side of the annular flange portion24. Further, the annular recessed engagement groove27is integrally formed on the lower side of the flange portion24.

As shown inFIGS. 1 to 3andFIGS. 5 to 7, the mounting bracket30is made of a synthetic resin. A tubular arm-supporting portion31having a circular inner peripheral surface31arotatably supporting the cylindrical-end portion21of the arm20is integrally protruded and formed at the center of the mounting bracket30. As shown inFIGS. 3, 5, and 8, the cylindrical-end portion21of the arm20is press-fitted to the inner peripheral surface31aof the arm-supporting portion31, and a locking protrusion32protruding from the inner peripheral surface31aenters the annular recessed engagement groove27of the arm20, and is engaged with the annular flange portion26. Accordingly, the upper side of the cylindrical-end portion21of the rotating arm20protrudes outside the arm-supporting portion31such that the upper side is exposed.

As shown inFIG. 5, a recess35for assembling the connector is formed on both sides of the arm-supporting portion31on the upper surface30aof the mounting bracket30and toward a mounting hole33of the mounting bracket30. An engagement hole36into which a locking piece portion43bof both side walls43and43of the connector40is fitted is formed on both sides of the recess35for assembling the connector toward a mounting hole34, which is opposite the side of the mounting hole33. In addition, as shown inFIGS. 5 and 6, a locking claw portion37to which the locking piece portion42aof a housing body42of the connector40is locked is formed at the center of the recess35for assembling the connector toward the mounting hole33. The mounting bracket30is screwed to a roof trim60by screws (not shown) via a pair of mounting holes33and34.

As shownFIG. 4, a housing41of the connector40is made of a synthetic resin. This housing41includes the housing body42, a pair of side walls43and43having a L-shaped terminal receiving chamber43aon both sides of the housing body42, and a center wall45where a hollow portion44is formed between the center wall (protruding wall)45and the center of the housing body42. As shown inFIG. 5, when the housing41is assembled in the recess35for assembling the connector so that the pair of side walls43and43of the housing41is positioned on both sides of the arm-supporting portion31of the mounting bracket30, as shown inFIG. 7, the cylindrical-end portion21of the arm20is exposed in the hollow portion44between the housing body42and the center wall45.

As shown inFIGS. 4, 5, 7, and 8, a pair of lubricating oil reservoirs46and46is integrally formed in a box shape at a position facing the arcuate-plate-shaped contact part29B on the lower side of the center wall45of the connector40to store paste-like grease (lubricating oil) G to be supplied to the arcuate-plate-shaped contact part29B on the lower side of the center wall45. Each lubricating oil reservoir46has a lubricating oil supply port46afor supplying the grease G to the arcuate-plate-shaped contact part29B on the lower side. An arcuate planar cutout46cof the bottom wall portion46hof each lubricating oil reservoir46on the lubricating oil supply port46aside is formed along the arcuate-plate-shaped contact part29B on the lower side. A certain amount of grease G is continuously supplied to the arcuate-plate-shaped contact part29B on the lower side through the arcuate planar cutout46c. Further, in the hollow portion44between the housing body42and the center wall45of the housing41, a pair of arcuate-plate-shaped contact parts29A and29B and spring portions52of a pair of terminals50and50to be described later are arranged facing to each other. That is, since each of the spring portion52having the contact portion53of the pair of terminals50and50is covered with the center wall45provided with the pair of lubricating oil reservoirs46and46, it is possible to reliably prevent the spring portion52of the terminal50from being deformed due to an external force.

Further, as shown inFIGS. 4 and 5, a cutout hole47having a rectangular cross section is formed between the pair of lubricating oil reservoirs46and46of the center wall45. An engaging protrusion48for assembling integrally protrudes and is formed on the lower side of the cutout hole47. If the position of the cylindrical end portion21of the arm20is not at the correct assembling position, it is impossible to attach the connector40to the mounting bracket30, that is, the engaging protrusion48for assembling the housing41cannot enter the annular recessed engagement groove25of the arm20from the cutout24aof the annular flange portion24. After assembling the connector40to the mounting bracket30, the engaging protrusion48is engaged with the annular flange portion24by the rotation of the arm20, so that the arm20is held by the housing41.

As shown inFIG. 4, each terminal50whose distal end is a box-shape mating-terminal connecting part51is formed in an L-shaped plate shape and housed in the L-shaped terminal receiving chamber43aof the side wall43of the housing41. In addition, the L-shaped plate spring portion52connected to the mating-terminal connecting part51of each terminal50is formed to be elastically deformable. In addition, the distal end of each spring portion52is provided with the semicircular spherical contact portion53. Further, the height of each spring portion52is different so as to correspond to the upper and lower arcuate-plate-shaped contact parts29A and29B.

As shown inFIG. 2, the connector40is adapted to be fitted into a connector62connected to a power supply connection wire61toward the roof trim60. At the time of this fitting, each mating-terminal connecting part51of the pair of terminals50and50of the connector40and the pair of terminals (not shown) of the connector62toward the roof trim60are electrically connected, and electric power is supplied to the pair of terminals50and50of the connector40.

Further, when the sun visor body11is folded in front of the front window and when the sun visor body11is folded to the side of the side window, the pair of arcuate-plate-shaped contact parts29A and29B provided on the outer peripheral surfaces22aand23aof the small-diameter and large-diameter cylindrical-end portions22and23is brought into contact (conducting) with the contact portion53of each spring portion52of the pair of terminals50and50for supplying electric power to be in a conducting (ON) state. That is, the conductive circuit connecting the pair of conductors28and28routed in the arm20and the illumination lamp13of the sun visor body11is in a conducting state, whereby the lighting preparation state of the illumination lamp13of the sun visor body11is generated. In this lighting preparation state, when a cover (slide member)14covering a vanity mirror12of the sun visor body11is opened by sliding, the switch mechanism (not shown) is turned on, and the illumination lamp13is turned on. Generally, when the sun visor body is folded to the side of the side window, the contact part toward the arm is away from the contact portion of the terminal for supplying electric power to becomes non-conductive, so that the conductive circuit of the illumination lamp is in a non-conducting (OFF) state. However, in the first embodiment, even when the sun visor body11is folded to the side of the side window, the pair of arcuate-plate-shaped contact parts29A and29B contacts each contact portion53of the pair of terminals50and50for supplying electric power, and the conductive circuit of the illumination lamp13is in a conducting state except when the connector40is assembled to the mounting bracket30.

According to the vehicle sun visor10of the first embodiment as described above, when the vehicle sun visor10is assembled, first, as shown inFIG. 3, the cylindrical-end portion21of the arm20is press-fitted to a circular inner peripheral surface31aformed obliquely in the arm-supporting portion31of the mounting bracket30. By this press-fitting, as shown inFIGS. 3, 5, and 8, the locking protrusion32protruding from the inner peripheral surface31aof the arm-supporting portion31enters the annular recessed engagement groove27of the arm20, and is engaged with the annular flange portion26, and the cylindrical-end portion21of the arm20is rotatably supported on the arm-supporting portion31.

Next, as shown inFIGS. 4 and 5, after the pair of terminals50and50is inserted into the housing41of the connector40, as shown inFIG. 5, cutouts22band23bof the small-diameter and large-diameter cylindrical-end portion22and23of the arm20, wherein the small-diameter and large-diameter cylindrical-end portion22and23is exposed outside the arm-supporting portion31of the mounting bracket30, is positioned to be faced with the both side walls43and43of the connector40. In this state, as shown inFIG. 6, the pair of locking piece portions43band43bprovided on the both side walls43and43of the housing41of the connector40is inserted into the pair of engagement holes36and36provided in the recess35for assembling the connector wherein the recess is provided on the upper surface30aof the mounting bracket30, and the connector40is rotated to lock the locking piece portion42aof the housing body42of the connector40to the locking claw portion37of the recess35for assembling the connector, as shown by the arrow inFIG. 6, so that the connector40is attached to the upper surface30aof the mounting bracket30.

At this time, each spring portion52having the contact portion53of the pair of terminals50and50assembled to the housing41of the connector40passes the vicinity of the cutouts22band23bof the small-diameter and large-diameter cylindrical-end portions22and23of the cylindrical-end portion21of the arm20. Therefore, the connector40can be assembled to the mounting bracket30while each spring portion52does not contact the pair of arcuate-plate-shaped contact parts29A and29B on the outer peripheral surfaces22aand23aof the small-diameter and large-diameter cylindrical-end portions22and23. As a result, there is no interference between the pair of arcuate-plate-shaped contact parts29A and29B and the contact portion53of each spring portion52of the pair of terminals50and50, and deformation of each spring portion52of the pair of terminals50and50can be reliably prevented.

The arcuate-plate-shaped contact parts29A and29B are provided on the outer peripheral surface22aof the small-diameter cylindrical-end portion22on the upper side of the arm20exposed outside the arm-supporting portion31of the mounting bracket30and the outer peripheral surface23aof the large-diameter cylindrical-end portion23on the lower side of the arm20exposed outside the arm-supporting portion31of the mounting bracket30, so that it is possible to widen the contact range (rotation angle of the arm20) between the arcuate-plate-shaped contact parts29A and29B serving as the contact part of the conductor28of the arm20and the contact portion53of the terminal50. As shown inFIG. 2, when the sun visor body11is stored toward the roof trim60and when the sun visor body11is folded in front of the front window, and when the sun visor body11is folded to the side of the side window, the pair of arcuate-plate-shaped contact parts29A and29B of the arm20and each contact portion53of the pair of terminals50and50can be in a contacting state.

Further, as shown inFIG. 8, at the position facing the outer peripheral surface23aof the large-diameter cylindrical end portion23of the cylindrical end portion21of the arm20of the center wall45of the connector40, the pair of lubricating oil reservoirs46and46for storing paste-like grease (lubricating oil) G to be supplied to the arcuate-plate-shaped contact part29B provided on the outer peripheral surface23aof the large-diameter cylindrical end portion23. As a result, paste-like grease G with which each lubricating oil reservoir46filled is supplied to the arcuate-plate-shaped contact part29B and adheres to the contact portion53of the terminal50. Therefore, it is possible to protect both the contact part29B and the contact portion53from wearing due to sliding. That is, the paste-like grease G stored in the lubricating oil reservoir46is constantly in contact with the arcuate-plate-shaped contact part29B and even if the arm20repeatedly rotates, the grease G surely adheres to the contact portion53of the terminal50. Thus, absence of grease G (grease out) will not occur due to sliding. That is, the grease G is constantly supplied between the arcuate-plate-shaped contact part29B and the contact portion53, and sliding abrasion between the contact part29B and the contact portion53can be surely prevented.

Further, after assembling the connector40to the mounting bracket30, the grease G is put into the lubricating oil reservoir46. Therefore, there is no concern that the grease G adheres to other parts at the time of assembling parts. In addition, the replenishment amount of the grease G is constant, and it is easy to determine whether the grease G is in contact with the arcuate-plate-shaped contact part29B of the arm20.

Further, the center wall45integrally protrudes from the housing41of the connector40at a position where the respective spring portions52having the contact portion53so as to cover the pair of spring portions52and52. Since the pair of spring portions52and52is covered by the center wall45in this way, it is possible to easily and reliably prevent the deformation of the spring portion52due to the external force.

FIG. 9is a perspective view showing a state before a cylindrical end portion of the arm is press-fitted to a mounting bracket of the vehicle sun visor according to a second embodiment of the present invention.FIG. 10is a perspective view showing a state before the connector is assembled to the mounting bracket to which the arm is attached.

As shown inFIGS. 9 and 10, an annular recessed groove portion21cis formed at the center of the outer peripheral surface21bof cylindrical end portion21, which is exposed outside of an arm-supporting portion31of the mounting bracket30′ of the arm20′, which will be described later. In the annular recessed groove portion21c, the pair of arcuate-plate-shaped contact parts29and29positioned on the ends of the pair of conductors28and28is arranged at the same height in the direction in which the arm20′ extends with a predetermined gap (interval) S. The pair of gaps S and S has respective arcuate recessed groove portions21dformed therein, and each arcuate recessed groove portion21dis a non-contact region between the pair of arcuate-plate-shaped contact parts29and29and each contact portion53of the pair of terminals50and50. Further, the spring portions52of the pair of terminals50and50are positioned at the same height position so as to correspond to the pair of arcuate-plate-shaped contact parts29and29. Paste-like grease (lubricating oil) G is always supplied to the pair of arcuate-plate-shaped contact parts29and29from a pair of box-like lubricating oil reservoirs46and46formed in the center wall45of the connector40housing41. Since other configurations are similar to those of the first embodiment, the same components are denoted by the same reference numerals, and a detailed description thereof will be omitted.

According to the second embodiment, since the paste-like grease G with which the pair of lubricating oil reservoirs46and46of the center wall45of the connector40is filled is always supplied to the pair of arcuate-plate-shaped contact parts29and29to adhere to the respective contact portions53of the pair of terminals50and50, it is possible to protect both the contact part29and the contact portion53from abrasion due to sliding. That is, as in the first embodiment, even if the arm20is repeatedly rotated, the grease G surely adheres to the contact portions53of the pair of terminals50and50, so that the grease G does not disappear by sliding. That is, the grease G is always supplied between the pair of arcuate-plate-shaped contact parts29and29and the respective contact portions53of the pair of terminals50and50to reliably prevent sliding abrasion between the contact part29and the contact portion53.

According to each of the above embodiments, the sun visor body is provided with an illumination lamp as an electrical component. The sun visor body may be provided with a compact and thin liquid crystal monitor or the like as an electrical component.

Moreover, the effects described in the embodiments of the present invention are only a list of optimum effects achieved by the present invention. Hence, the effects of the present invention are not limited to those described in the embodiment of the present invention.