Molding for vehicle and method for manufacturing same

An elongated molding for a vehicle, including: a main body including, a head portion arranged at a front surface side of a circumferential edge of a window pane, a leg portion protruding from a back surface of the head portion and being arranged to face an end surface of the circumferential edge of the window pane, and a foot portion protruding from a tip of the leg portion toward a center of the window pane, wherein a volume raising portion is integrally provided to at least a portion of a back surface of the head portion in a longitudinal direction thereof, wherein a thickness of the volume raising portion varies at at least some positions in the longitudinal direction, and wherein the volume raising portion is made of a resin material softer than a resin material constituting the head portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from Japanese Patent Application No. 2013-182835 filed on Sep. 4, 2013, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

Aspects of the present invention relate to an elongated window molding (hereinafter, simply referred to as a “molding”) to be attached to, for example, a circumferential edge of a front window glass for a vehicle. Vehicles to which the window molding is applied include automobiles, buses, trucks, and the like.

BACKGROUND

Various types of window moldings made of metal, resin, etc., are known. As a window molding made of resin, which is molded by extrusion molding or injection molding, a type that is attached to a circumferential edge of a window pane by pinching the circumferential edge of the window pane from three directions of a front surface, a back surface, and an end surface of a window glass (window pane) so as to surround a circumference edge of the window pane is known. Further, in elongated moldings, there is known an isomorphic type (same cross-sectional type) in which the cross-sectional shape in a longitudinal direction is constant. However, a number of types (variant cross-sectional types) of which the cross-sectional shape in the longitudinal direction varies are also known.

Among the variant cross-sectional type resinous moldings, for example, there is a molding designed such that a height difference (h) between a front surface of a decorative portion of the molding attached to a side portion (a left side or a right side of a vehicle) of a window glass and a front surface of the window glass (window pane) becomes gradually larger in the downward direction of the window glass, from viewpoints of functionality and designability. Such moldings include moldings shown in JP-A-H03-128721 and JP-A-2003-165137. The molding of JP-A-H03-128721 is formed through extrusion molding, and is intended to be attached to an upper portion and side portions (left and right side portions) of a front window glass. The molding of JP-A-2003-165137 is formed through injection molding, and is intended to be attached to the side portions (left and right side portions) of the front window glass.

SUMMARY

However, there are the following disadvantages in the molding techniques of JP-A-H03-128721 and JP-A-2003-165137. First, in order to mold a molded product, in which variant cross-sections continue in a longitudinal direction, through the extrusion molding, a special technique or apparatus that changes cross-sections during extrusion is required. Further, the degree of technical difficulty is high, and the manufacturing cost may increase.

Meanwhile, according to the injection molding, there is little difficulty in molding the molded product in which the variant cross-sections continue in the longitudinal direction. However, in order to realize the variant cross-sections, it is necessary to additionally form a portion for raising (build-up) the volume on a back surface of the decorative portion opposite to the front surface of the decorative portion (that is, decorative face) with the same resin material as the decorative portion. Accordingly, a forming mold and a cavity structure that enables the portion for raising the volume on the back surface of the decorative portion to be formed are adopted. However, if an attempt to secure such a volume raising portion as described above is made, a place with thick resin and a place with thin resin are likely to be formed in a longitudinal direction of a molded product, which may cause local sink (recesses) in the decorative face. That is, if there is a local difference in the thickness of molten resin in the longitudinal direction of the product, a difference is also caused in the degree of shrinkage of the molten resin due to the difference in the thickness, which results in impairing the external appearance of the decorative face. More specifically, since the degree of sink is high in places with thick resin and the degree of sink is low in places with thin resin, there is a concern that a difference between the degrees of sink according to positions may cause an adverse effect on the external appearance of the decorative face (for example, there is a concern that an impression that the external appearance is uneven may be given).

Aspects of the invention has been made in view of the above circumstances, and an object thereof is to provide a molding for a vehicle, which is capable of being molded by injection molding and realizing a favorable external appearance, and a method for manufacturing the same.

According to a first aspect of the invention, there is provided an elongated molding for a vehicle, which is configured to be attached to a circumferential edge of a window pane of a vehicle, the molding including: an elongated main body including, a head portion arranged at a front surface side of the circumferential edge of the window pane and providing a decorative face when the molding is attached to the window pane, a leg portion protruding from a back surface of the head portion and being arranged to face an end surface of the circumferential edge of the window pane when the molding is attached to the window pane, and a foot portion protruding from a tip of the leg portion toward a center of the window pane and being arranged at a back surface side of the circumferential edge of the window pane when the molding is attached to the window pane, wherein at least a portion of the main body in a longitudinal direction thereof has a substantially U-shaped cross-sectional shape formed by the head portion, the leg portion, and the foot portion, wherein a volume raising portion is provided integrally with the head portion on the back surface of the head portion, the volume raising portion being provided to at least a portion of the head portion in the longitudinal direction, wherein a thickness of the volume raising portion varies at at least some positions in the longitudinal direction, and wherein the volume raising portion is made of a resin material softer than a resin material constituting the head portion.

Accordingly, the following effects are obtained. That is, since the main body of the elongated molding has a cross-sectional shape that is a substantially U-shape formed by the head portion, the leg portion, and the foot portion, the window pane can be held from the front surface thereof to the back surface thereof. Accordingly, once this molding is mounted on a vehicle, there is no concern that the molding easily slips out of the window pane. Additionally, the volume raising portion that is additionally formed in order to realize variant cross-sections along the longitudinal direction of the main body of the molding is provided integrally with the head portion of the main body, and the thickness of the volume raising portion varies at at least some positions in the longitudinal direction, but the resin material constituting the volume raising portion is different from the resin material constituting the head portion. Therefore, even when the volume raising portion is molded by injection molding, the problems of sink can be lessened (or non-actualized), and the external appearance of the front surface (that is, the decorative face) of the head portion can be kept favorable. Moreover, since the volume raising portion that abuts with the front surface of the circumferential edge of the window pane is made of the resin material softer than the resin material constituting the head portion, damage on the window pane and generation of abnormal noise can be prevented.

According to a second aspect of the invention, there is provided a method for manufacturing the molding for a vehicle according to the first aspect, the method including: performing primary molding by injection-molding a primary molded product including at least the head portion of the main body of the molding; and performing secondary molding by arranging the primary molded product as an insert in a forming mold and injection-molding the volume raising portion to the primary molded product by using the resin material softer than the resin material constituting the head portion.

Accordingly, the following effects similar to the effects of the first aspect can be obtained. That is, according to the method of the invention, the main body including the head portion is injection-molded to mold the primary molded product in advance. Thereafter, the volume raising portion can be injection-molded to the primary molded product on the back side of the head portion to obtain the secondary molded product (finished product). Therefore, even if the molten resin constituting the volume raising portion in the secondary molding process has shown a difference in shrinkage amount according to a difference in thickness of the volume raising portion, the influence of sink caused by the secondary molding process is merely actualized on the back surface of the head portion at the utmost, and the front surface of the head portion (that is, the decorative face) that is already finished in the primary molding process is not influenced at all. Since the injection molding is divided into the two processes (separate processes) on the surface side and back side of the head portion in this way, there is no concern that the external appearance of the decorative face may be impaired even if the volume raising portion is additionally formed in order to realize variant cross-sections in the longitudinal direction.

DETAILED DESCRIPTION

Hereinafter, a window molding according to first embodiment of the invention will be described referring to the drawings.

FIG. 1is a perspective view of a portion of a cabin (passenger cabin) of a general sedan type automobile, as viewed from an oblique front side. As illustrated inFIG. 1, a cabin1is surrounded and molded by a roof panel2(ceiling portion), side panels3located on both left and right sides (only a right side panel is illustrated), and other panel members (not illustrated). Although a panel constituting the cabin1is generally made of metal, in an example ofFIG. 1, junctions between side portions of the roof panel2and the side panels3are provided with a roof molding4made of resin. The side panels3extend further forward than a front edge of the roof panel2and obliquely downward. Additionally, front extended portions3a(generally, referred to as “front pillars” or “A pillars”) of the side panels3are arranged on both left and right side portions of a front window glass5(hereinafter, referred to as “window pane”). Moldings10of the present embodiment are elongated resin members that are arranged along the front extended portions3aof the side panels and are interposed between the front extended portions3aand the side portions of the window pane5to guarantee a decorative function, a waterproof function, and other functions.

The molding10of the present embodiment is attached to a vehicle body together with the window pane5after being adhered to the side portion of the window pane5forming a portion of a circumferential edge of the window pane5, using a double faced adhesive tape6(refer toFIGS. 2 and 3). In that case, a lower portion11(lower end portion) of the molding10is put under a cowl portion7of the vehicle body. Meanwhile, an upper portion12(upper end portion) of the molding10is formed in a curved manner corresponding to a corner portion5aof an upper portion of the window pane, and the corner portion5aof the upper portion of the window pane is partially covered with the upper portion12. The upper portion12of the molding is arranged adjacent to a front end portion of the roof molding4.

FIG. 2is a front view of the molding10for a right side interposed between the front extended portion3aof a right side panel and a right side portion of the window pane5ofFIG. 1. Although the molding for the right side and a molding for a left side, which is line-symmetrical to the molding for the right side, are mounted on an actual vehicle in a pair, only the molding for the right side will be described in the present specification and drawings.

As illustrated inFIG. 2, a main body of the molding10has a vertically long shape, and the upper portion12curved leftward with respect to the main body is provided in the vicinity of an upper end portion of the main body. The line IV-IV inFIG. 2is generally a boundary between the upper portion12and a main body portion other than the upper portion. In the main body of the molding, the whole remaining portion other than the upper portion12may be referred to as a “side portion”. This naming originates from a fact that the remaining portion other than the upper portion12is a portion corresponding to the side portion of the window pane5. The front of the main body of the molding illustrated inFIG. 2is a front surface, and this front surface corresponds to a decorative face16. Additionally, although respective portions that are present on a back side of the main body of the molding are drawn by dashed lines inFIG. 2, these portions will be described later with reference to a plurality of cross-sectional views.

The molding10of the present embodiment is formed by two-process injection molding using two types of resin materials, that is, a “hard resin (material)” and a “soft resin (material)”. Here, the “hard” and the “soft” are terms that express the relative relationship of hardness or softness between these two resin materials. The “hard resin (material)” means a resin material, which is harder than the soft resin (material), and the “soft resin (material)” means a resin material, which is softer than the hard resin (material). Although the hard resin (material) and the soft resin (material) are generally made of different materials, the hard resin (material) and the soft resin (material) can also be prepared from the same kind of resin material, so long as the hard and soft reins (materials) can be separately prepared depending on differences in molecular weight or the presence or absence of a plasticizer and other additives even if substantially the same material is used. Preferable hard resins (materials) include AES resins, ABS resins, PP resins, PPO resins, polycarbonate (PC) resins, polyamide (PA) resins, or alloy resins thereof. Preferable soft resins (materials) include thermo-polyolefin (TPO) resins. TPO is a generic term of thermoplastic olefins (homopolymers or copolymers), behaves like elastomers (elastic bodies) and has rubber-like properties at room temperature, but has unique properties capable of being molded similar to general-purpose plastics. As TPO, those obtained by finely dispersing ethylene-propylene rubber (EPDM, EPM) in polypropylene (PP) can be exemplified. In instances illustrated inFIGS. 2 to 11, acrylonitrileethylene-propylene-dienestyrene (AES) resins are used as the hard resin, and TPO is used as the soft resin.

FIG. 3illustrates a cross-section taken along line III-III ofFIG. 2, that is, a cross-sectional view at a substantially central position of the molding10in a longitudinal direction. In cross-sectional views ofFIG. 3and the subsequent drawings (FIGS. 3 to 8), respective upper, lower, left, and right directions (respective sides) on the drawing sheets are referred to in the following manner in association with the window pane5. That is, on the drawing sheet planes, an upper side is referred to as an “exterior side (front surface side)”, a lower side is referred to as an “interior side (back surface side)”, a left side is referred to as an “inner circumference side”, and a right side is referred to as an “outer circumference side”.

As illustrated inFIG. 3, the main body of the molding10includes a head portion15, a leg portion20, and a foot portion30. The “head portion15” indicates a portion that is located at the front surface side of the circumferential edge of the window pane and is arranged further toward the exterior side than the surface of the window pane5when the molding10is attached to the window pane5. The “decorative face16” of the molding10is provided by an upper surface16of the head portion15. The “leg portion20” indicates a portion that protrudes downward (toward the interior side) from the back surface in the vicinity of the end portion of the head portion15on the outer circumference side and that faces an end surface of the circumferential edge of the window pane when the molding10is attached to the window pane5. The “foot portion30” indicates a portion that protrudes toward the center of the window pane5from a lower end portion of the leg portion20and that is located at the back side of the circumferential edge of the window pane and is arranged further toward the interior side than the back surface of the window pane5when the molding10is attached to the window pane5. The cross-sectional shape of the main body of the molding is a substantially U-shape formed by the head portion15, the leg portion20, and the foot portion30. Here, in the present embodiment, although the cross-sectional shape of the main body of the molding is a substantially U-shape over the total length of the main body of the molding, the invention is not limited thereto. For example, the foot portion30is intermittently or partially formed in the longitudinal direction of the main body of the molding. As a result, the cross-sectional shape of the main body of the molding may be intermittently or partially a substantially U-shape. In this case, the cross-sectional shape of the main body of the molding is a substantially T-shape in the portion in which the foot portion30is not formed.

In the molding10of the present embodiment, the head portion15is basically formed of a hard resin. Although the leg portion20is mostly made of the hard resin, a portion formed of a soft resin is partially included in the leg portion. The foot portion30is also formed by combining the hard resin and the soft resin. As illustrated by a dashed line A inFIG. 3, the height and thickness of the head portion15is set so that the upper surface16of the head portion15and the surface of the side panel3become substantially flush with each other.

A gas channel17is provided within the head portion15over the entirety of the head portion15in the longitudinal direction and in the vicinity of the boundary between the head portion15and the leg portion20. The gas channel17is a trace of when a primary molded product formed of a hard resin is molded by gas injection molding. Additionally, a lip portion21made of a soft resin is provided on the outer circumference side of the leg portion20. The lip portion21serves as a waterproof seal as a tip portion thereof abuts on the side panel3and is deformed (however, a non-deformed state is illustrated in cross-sectional views ofFIG. 3and other drawings). Meanwhile, at a cross-sectional position ofFIG. 3, the end surface of the window pane5does not abut on an inner circumference side lateral surface of the leg portion20, and a gap S is formed between both the surfaces. Additionally, an upper half portion31of the foot portion30that comes into contact with the back surface of the window pane5is basically formed of a hard resin, and a lower half portion32that comes into contact with the side panel3is formed of a soft resin.

Moreover, as illustrated inFIG. 3, the volume raising portion18is formed integrally with the head portion15on the back surface of the head portion15so as to fill a space between the head portion15and the window pane5. The head portion15is made of the hard resin, whereas the volume raising portion18is made of a soft resin. As illustrated inFIG. 2, the volume raising portion18is provided along the head portion15over a wide range from a lower side of line IV-IV ofFIG. 2to a lower side of line VII-VII ofFIG. 2. Additionally, the total length of the volume raising portion18along the head portion15is approximately equal to the length of the side portion of the window pane5. However, the thickness (t) of the volume raising portion18is not necessarily equal at respective positions along the longitudinal direction (described later with reference toFIGS. 4 to 8).

As illustrated inFIG. 3, the double faced adhesive tape6is interposed between a lower surface of the volume raising portion18and an upper surface (front surface) of the window pane5, and the molding10is fixed to the window pane5by the double faced adhesive tape6. As illustrated inFIG. 2, the double faced adhesive tape6is adhered along the head portion15over a wide range from the lower side of line IV-IV inFIG. 2to a portion immediately before a lower edge of the main body of the molding. As can be seen fromFIG. 2, the width of the double faced adhesive tape6is narrower than the width (a length in a horizontally traversing direction inFIG. 2) of the volume raising portion18.

A urethane sealant U (illustrated by an imaginary line inFIG. 3) may be put along the foot portion30of the molding between the side panel3and the window pane5.

FIG. 4illustrates a cross-section taken along line IV-IV ofFIG. 2, that is, a cross-section of the upper portion12of the molding10at a position near the boundary with the side portion. Although the molding10(upper portion12) at this cross-sectional position has the head portion15and the leg portion20both of which are made of the hard resins and the lip portion21made of a soft resin, the foot portion30is not included (however, the foot portion may be provided). Additionally, the volume raising portion18is not provided (if the thickness of the volume raising portion18, in which the back surface of the head portion15as a reference line, is defined as t, t=0). If the height or distance from the front surface of the window pane5to a front surface (upper surface16) of the head portion15is defined as h, h=h0is set at the position ofFIG. 4.

FIG. 5illustrates a cross-section taken along line V-V ofFIG. 2, that is, a cross-section at a position where a rib portion22is provided, on the inner circumference side of the leg portion20, in the side portion of the molding10.FIG. 6illustrates a cross-section taken along line VI-VI ofFIG. 2, that is, a cross-section at a position where a thick portion23is provided, on the inner circumference side of the leg portion20in the side portion of the molding10. As illustrated by a dash line inFIG. 2(front view) and illustrated inFIG. 9(a side view of a partial interval), a plurality of (a total of nine in the present example) the rib portions22and a plurality of (a total of three in the present example) the thick portions23are provided on the inner circumference lateral surface of the leg portion20of the molding10so as to protrude at intervals (that is, intermittently) in the longitudinal direction. Both of the rib portions22and the thick portions23are formed of soft resins, and function as cushion projections that abut on the end surface of the circumferential edge of the window pane and prevent a damage of the window pane5or generation of abnormal noise when the molding10is attached to the window pane5. The designation of the “rib portions22” and the “thick portions23” originates from the relative width and narrowness of the respective portions in a side view (refer toFIG. 9), where relatively narrow rib-shaped ridges are referred to as the “rib portions22” and relatively wide belt-shaped projections are referred to as the “thick portions23”. According toFIG. 2, three thick portions (23A,23B, and23C in order from the upper side) are arranged at three places where the total length of the side portion of the molding10is almost divided into four. Also, two rib portions22are arranged at two places between the upper portion12and an upper thick portion23A, two rib portions22are arranged at two places between the upper thick portion23A and a middle thick portion23B (refer toFIG. 9), two rib portions22are arranged at two places between the middle thick portion23B and a lower thick portion23C, and three rib portions22are arranged at three places lower than the lower thick portion23C.

As illustrated inFIG. 5, at this position, a main framework portion of the leg portion20is formed of the same hard resin as the head portion15. Hereinafter, the portion of the leg portion20that is formed of the same hard resin as the head portion15is referred to as a “main portion201of the leg portion20”. Additionally, the lip portion21made of the soft resin is provided on the outer circumference side of the leg portion20(main portion201), and a rib portion22made of the soft resin is provided on the inner circumference side lateral surface (surface facing the end surface of the window pane5) of the leg portion20. The rib portion22extends lengthwise from the interior side to the exterior side, and an upper end portion (exterior side end portion) of the rib portion22is formed continuously with the volume raising portion18. At a cross-sectional position ofFIG. 5, the height h from the front surface of the window pane5to the front surface (upper surface16) of the head portion15is set to h=h1, and this height h1is greater than the height h0inFIG. 4(h0<h1). Additionally, the thickness t of the volume raising portion18is set to t=t1.

A modification example of the cross-section ofFIG. 5is illustrated inFIG. 10. As illustrated inFIG. 10, a cushion abutting portion33made of a soft resin may be formed at a portion of the upper half portion31of the foot portion30that directly comes into contact with the back surface of the window pane5. The cushion abutting portion33also contributes to prevention of the generation of abnormal noise, similar to the rib portions22or the like. The cushion abutting portion33does not need to be a layered portion that is planarly developed, and may be provided as a rib-like projection.

As illustrated inFIG. 6, at this position, the framework portion of the leg portion20is formed of the same soft resin as the volume raising portion18. Hereinafter, the portion of the leg portion20that is formed of the same soft resin as the volume raising portion18and connected to the volume raising portion18is referred to as a “filled portion202of the leg portion20”. The lip portion21made of the soft resin is provided on the outer circumference side of the leg portion20(filled portion202). The filled portion202and the lip portion21are made of the same material. Meanwhile, a thick portion23(23A ofFIG. 9) made of a soft resin is provided on the inner circumference lateral surface (surface facing the end surface of the window pane5) of the leg portion20(filled portion202). The thick portion23extends in the longitudinal direction from the interior side to the exterior side, and an upper end portion (exterior side end portion) of the thick portion23is formed continuously with the volume raising portion18. The leg portion20(filled portion202) and the thick portion23are made of the same material. The position of a boundary line (dashed boundary line) between the leg portion20(filled portion202) and the thick portion23, which is drawn by a vertical dashed line inFIG. 6, corresponds to the position of the inner circumference side lateral surface of the leg portion20ofFIG. 3. Accordingly, the thickness of the thick portion23illustrated inFIG. 6is equivalent to the clearance (gap width) of the gap S ofFIG. 3. As can be seen fromFIG. 9, the width (length in the longitudinal direction of the molding10) of the thick portion23is a size approximately six times greater than the width of the rib portion22, and the thick portion23is a wide belt-shaped projection.

Additionally, as illustrated inFIG. 6, a half of the outer circumference side34of the upper half portion31of the foot portion30is formed of the same soft resin as the lower half portion32of the foot portion and the leg portion20(filled portion202). That is, the leg portion20(filled portion202) and the lower half portion32of the foot portion are connected to each other via the half of the outer circumference side34of the upper half portion31of the foot portion30made of the same soft resin.

Moreover, as illustrated inFIG. 6, the height h from the front surface of the window pane5to the front surface (upper surface16) of the head portion15is set to h=h2, and this height h2is greater than the height h0inFIG. 4and the height h1inFIG. 5(h0<h1<h2). That is, the height h of the head portion15with respect to the front surface of the window pane becomes greater gradually from the vicinity of the boundary with the upper portion12to the center of the molding10. However, the height h substantially reaches a peak at h2. Additionally, the thickness t of the volume raising portion18is set to t=t2, and this thickness t2is greater than the thickness t1inFIG. 5(t1<t2). That is, similar to the height h of the head portion15, the thickness t of the volume raising portion18tends to become higher gradually toward the center of the molding10. However, the thickness t also substantially reaches a peak at t2.

AlthoughFIG. 6illustrates a cross-sectional situation at the position of the upper thick portion23A, the cross-sectional situations are also substantially the same at the respective positions of the middle thick portion23B and the lower thick portion23C. That is, to describe the leg portion20provided to extend along the main body of the molding, in the leg portion20, the filled portions202(soft resin portions) located at the back or deep sides of the respective thick portions23are set at the respective positions where the three thick portions23A,23B, and23C are provided (refer toFIG. 6). Portions other than the three filled portions202that are intermittently arranged constitute the main portion201(hard resin portion) of the leg portion20(refer toFIGS. 3,4,5,7, and8). In this way, the leg portion20of the main body of the molding is formed by integrating the main portion201made of the same hard resin as the head portion15, and the three filled portions202of the main portion201made of the soft resin that are intermittently arranged along the longitudinal direction of the main body of the molding.

Additionally, with respect to the height h from the front surface of the window pane5to the front surface (upper surface16) of the head portion15, and the thickness t of the volume raising portion18, the height h and the thickness t at the respective positions of the middle thick portion23B and the lower thick portion23C are approximately equal to the height h2and the thickness t2at the position of the upper thick portion23A. That is, in the central interval of the main body of the molding from the upper thick portion23A to the lower thick portion23C, the height h of the head portion15is substantially constant at h=h2, and the thickness t of the volume raising portion18is substantially constant at t=t2.

FIG. 7illustrates a cross-section taken along line VII-VII ofFIG. 2, that is, a cross-section at a position where a rib portion22is present, at the vicinity of a lower end of the side portion of the molding10(a position nearest to the lower portion11). At this position, the main portion201, which is formed of the same hard resin as the head portion15, occupies the leg portion20, and the lip portion21made of the soft resin is provided on the outer circumference side of the leg portion20(main portion201). Additionally, the rib portion22made of the soft resin is provided on the inner circumference side lateral surface (surface facing the end surface of the window pane5) of the leg portion20, similar toFIG. 5, and the upper end portion (exterior side end portion) of the rib portion22is formed continuously with the volume raising portion18. At a cross-sectional position ofFIG. 7, the height h from the front surface of the window pane5to the front surface (upper surface16) of the head portion15is set to h=h3, and this height h3is lower than the height h2inFIG. 6(h3<h2). Additionally, the thickness t of the volume raising portion18is set to t=t3, and this thickness t3is smaller than the thickness t2inFIG. 6(t3<t2). That is, the thickness t of the volume raising portion18becomes smaller gradually from the lower thick portion23C toward the lower portion11.

FIG. 8illustrates a cross-section taken along line VIII-VIII ofFIG. 2, that is, a cross-section at a position where a rib portion22is present, at the lower portion11of the molding10. At this position, the volume raising portion18is not present on the back surface of the head portion15(t=0), and the back surface of the head portion15is directly fixed to the front surface of the window pane5by the double faced adhesive tape6. Additionally, at this position, the main portion201, which is formed of the same hard resin as the head portion15, occupies the leg portion20, and the lip portion21made of the soft resin is provided on the outer circumference side of the leg portion20(main portion201). Additionally, the rib portion22made of the soft resin is provided on the inner circumference lateral surface (surface facing the end surface of the window pane5) of the leg portion20, similar toFIGS. 5 and 7.

Moreover, a portion36of the upper half portion31of the foot portion30that directly comes into contact with an inner circumference side lateral portion35and the back surface of the window pane5is formed of the same soft resin as the lower half portion32of the foot portion and the rib portion22. The portion36formed of the soft resin functions as at least a cushion abutting portion that contributes to prevention of the generation of abnormal noise, or the like, similar to the rib portion22. At a cross-sectional position ofFIG. 8, the height h from the front surface of the window pane5to the front surface (upper surface16) of the head portion15is set to h=h4, and this height h4is still lower than the height h3inFIG. 7(h4<h3<h2). That is, the height h of the head portion15is set so as to become lower gradually from the lower thick portion23C toward the lower portion11.

Next, a method for manufacturing the molding10of the present embodiment will be described. The molding10is manufactured through two injection-molding processes including a primary molding process of injection-molding a primary molded product (intermediate body) by using a hard resin, and a secondary molding process of using the primary molded product as an insert and injection-molding a secondary molded product by using a soft resin.

The primary molding process is a process of gas-injection-molding the portion of the main body of the molding that is made of the hard resin (that is, the main framework portion). A primary molded product P1(refer toFIG. 11), in which the head portion15, the main portion201of the leg portion20, and the hard resin portion of the foot portion30(for example, the upper half portion31of the foot portion) in the molding are formed as an integral article, is molded by this first injection molding. In this primary molding process, only the main portion201of the leg portion20is molded, and the leg portion20only including of the main portion201has a shape in which places serving as the filled portions202(three places corresponding to the thick portions23) are intermittently cut out. Since the primary molded product P1has a shape in which portions of the main portion201of the leg portion are intermittently cut out along a longitudinal direction of the primary molded product P1, the degree of shrinkage after the molding of the primary molded product P1in the longitudinal direction can be kept low. As a result, deflection or twisting of the main body of the molding resulting from the shrinkage after the molding can be suppressed.

The secondary molding process is a process of adding a portion made of a soft resin to the primary molded product P1as an insert through injection molding. More specifically, the injection molding is performed using a molding mechanism40as illustrated inFIG. 11. The molding mechanism40ofFIG. 11includes a fixed mold41, a movable mold44capable of approaching and separating from the fixed mold41, and a left slide core42and a right slide core43capable of advancing and retracting on both left and right sides of the movable mold44. When injection molding is performed, first, the primary molded product P1as an insert is set on the movable mold44that has separated from the fixed mold41, and then, the left slide core42and the right slide core43are advanced toward the movable mold44and positioned as illustrated inFIG. 11. Subsequently, the movable mold44, the left slide core42and the right slide core43are brought close to the fixed mold41and arranged at a molding position illustrated inFIG. 11, whereby the movement of the primary molded product P1is constrained and the primary molded product P1is held at a predetermined position. In this way, a cavity C is constructed by the primary molded product P1and the inner surfaces of the respective molds and cores. The cavity C is filled with a soft resin in a molten state via a sprue45provided in the fixed mold41, a runner46formed between the fixed mold41and the right slide core43, and a gate47set at a position on the tip of the runner46. In this way, a secondary molded product in which the volume raising portion18and the other portions made of the soft resin are added to the primary molded product P1is formed. The three thick portions23that are intermittently arranged along the longitudinal direction of the molding10are formed at positions where the gate47is present. The runner portion is removed after the secondary molded product is released from the molding mechanism40.

The secondary molded product in which the volume raising portion18, the filled portions202of the leg portion20, the lower half portion32of the foot portion30, and the other soft resin portions (for example, lip portion21, the rib portions22, the thick portions23, portions33,34,35, and36, and the like) are integrated with the primary molded product P1is obtained by the second injection molding. In this secondary molding, the filled portions202made of the soft resin are formed in the respective places of the main portion201of the leg portion that are intermittently cut out. By intermittently arranging the soft material in the hard material in this way, it is possible to suppress the rigidity of the entire molding to guarantee a predetermined flexibility, and it is easy to make the molding10to follow variations (dimensional errors or the like for every manufacturing lot) in the shapes of the window pane5and the side panels3of the vehicle.

According to the present embodiment, the main body including the head portion15is injection-molded to mold the primary molded product P1in advance. Thereafter, the volume raising portion18can be injection-molded to the primary molded product P1on the back side of the head portion15to obtain the secondary molded product (finished product). Therefore, even if the molten resin constituting the volume raising portion18in the secondary molding process has shown a difference in shrinkage amount according to a difference in thickness (t) at respective positions of the volume raising portion18, the influence of sink caused by the secondary molding process is merely actualized on the back surface of the head portion15at the utmost, and the front surface of the head portion15(that is, the decorative face16) that is already finished in the primary molding process is not influenced at all. Since the injection molding is divided into the two processes (separate processes) on the front surface side and back surface side of the head portion15in this way, there is no concern that the external appearance of the decorative face16may be impaired even if the volume raising portion18is additionally formed in order to realize variant cross-sections along the longitudinal direction. Incidentally, the volume raising portion18that comes in contact with the front surface of the circumferential edge of the window pane5is made of the resin material softer than the resin material constituting the head portion15, so that the damage of the window pane5and the generation of the abnormal noise of the window pane5can be prevented.

Other advantages and features of the present embodiment will be listed below.

Since the molding10of the present embodiment is mainly fixed to the window pane5by the double faced adhesive tape6adhered to the back surface of the volume raising portion18, mounting work to the window pane5is easy. Additionally, since the double faced adhesive tape6is used rather than glue, the molding10can be temporarily fixed during mounting work to the window pane5, and it becomes possible to flexibly deal with even subtle alignment. Additionally, since the width of the volume raising portion18is greater than the width of the double faced adhesive tape6in the direction of the cross-section of the molding10, a side edge of the tape6does not protrude to the outside of the volume raising portion18, and there is no concern that aesthetic appearance may be impaired.

The lip portion21that protrudes outward (outer circumferential direction) is provided on the outer circumference side of the leg portion20of the molding10. The lip portion21is able to perform a function, such as windproofing by abutting on a body (vehicle body) to block a gap between the window pane5and the body.

In the molding10of the present embodiment, the portions made of soft resin (for example, the lip portion21and the lower half portion32of the foot portion) are continuously formed over the entire longitudinal direction of the main body of the molding. For this reason, even when the soft resin portions abuts on the body (vehicle body) or the window pane5, the abutting states thereof are stable, and the generation of abnormal noise, or the like can be effectively prevented.

The portion in which the thickness t of the volume raising portion18gradually increases towards the lower side when the molding is attached to a vehicle (specifically, the interval of t=0<t1<t2from the cross-sectional line IV-IV ofFIG. 2to the cross-sectional line VI-VI thereof) is present at the volume raising portion18of the main body of the molding. This portion with gradually increasing thickness catches the water that has been wiped off by wipers and has flown to the side portions of the window pane5and guides the water upward or downward from the side portions of the window pane, so that the water can be prevented from getting over the molding and flowing to side windows.

The upper portion12located at the upper end of the molding10is formed in a curved manner corresponding to the shape of the corner portion5aof the upper portion of the window pane. Therefore, according to this molding10, the portion from the corner portion5aof the upper portion of the window pane to the lower end of the window pane5can be continuously covered. Therefore, aesthetic appearance is excellent.

The present invention provides illustrative, non-limiting examples as follows:

(1) In a first example, there is provided an elongated molding for a vehicle, which is configured to be attached to a circumferential edge of a window pane of a vehicle, the molding including: an elongated main body including, a head portion arranged at a front surface side of the circumferential edge of the window pane and providing a decorative face when the molding is attached to the window pane, a leg portion protruding from a back surface of the head portion and being arranged to face an end surface of the circumferential edge of the window pane when the molding is attached to the window pane, and a foot portion protruding from a tip of the leg portion toward a center of the window pane and being arranged at a back surface side of the circumferential edge of the window pane when the molding is attached to the window pane, wherein at least a portion of the main body in a longitudinal direction thereof has a substantially U-shaped cross-sectional shape formed by the head portion, the leg portion, and the foot portion, wherein a volume raising portion is provided integrally with the head portion on the back surface of the head portion, the volume raising portion being provided to at least a portion of the head portion in the longitudinal direction, wherein a thickness of the volume raising portion varies at at least some positions in the longitudinal direction, and wherein the volume raising portion is made of a resin material softer than a resin material constituting the head portion.

Accordingly, the following effects are obtained. That is, since the main body of the elongated molding has a cross-sectional shape that is a substantially U-shape formed by the head portion, the leg portion, and the foot portion, the window pane can be held from the front surface thereof to the back surface thereof. Accordingly, once this molding is mounted on a vehicle, there is no concern that the molding easily slips out of the window pane. Additionally, the volume raising portion that is additionally formed in order to realize variant cross-sections along the longitudinal direction of the main body of the molding is provided integrally with the head portion of the main body, and the thickness of the volume raising portion varies at at least some positions in the longitudinal direction, but the resin material constituting the volume raising portion is different from the resin material constituting the head portion. Therefore, even when the volume raising portion is molded by injection molding, the problems of sink can be lessened (or non-actualized), and the external appearance of the front surface (that is, the decorative face) of the head portion can be kept favorable. Moreover, since the volume raising portion that abuts with the front surface of the circumferential edge of the window pane is made of the resin material softer than the resin material constituting the head portion, damage on the window pane and generation of abnormal noise can be prevented.

(2) In a second example, there is provided the molding for a vehicle according to the first example, wherein the leg portion of the main body includes, a main portion made of the same resin material as the resin material constituting the head portion, and a plurality of filled portions that are provided in the main portion and are intermittently arranged in the longitudinal direction of the main body, and wherein each filled portion of the leg portion is made of the same resin material as the resin material constituting the volume raising portion.

Accordingly, in addition to the effects of the first example, the following effects can be further obtained. That is, in the leg portion, the plurality of filled portions, which are provided in the main portion made of the same hard resin material as the resin material constituting the head portion and are made of the resin material softer than the resin material constituting the head portion, are intermittently arranged in the longitudinal direction. That is, in the primary injection molding, only the main portion in a state where portions which become the filled portions by the secondary injection molding are intermittently cut out is molded. Therefore, the degree of shrinkage after the molding in the longitudinal direction can be kept low. As a result, deflection or twisting of the main body of the molding resulting from the shrinkage after the molding can be suppressed. Additionally, in the leg portion, by the second injection molding, the filled portions made of a relatively soft resin material are formed to a plurality of places that are intermittently cut out. By intermittently arranging the soft material in the hard resin in this way, it is possible to suppress the rigidity of the entire molding to guarantee a predetermined flexibility, and it becomes easy to make the molding to follow variations (dimensional errors or the like for every manufacturing lot) in the shapes of the window pane and the vehicle body panels.

(3) In a third example, there is provided the molding for a vehicle according to the first or second example, wherein a plurality of cushion projections are intermittently arranged in the longitudinal direction of the main body on an inner circumferential lateral surface of the leg portion that faces the end surface of the circumferential edge of the window pane, and wherein the plurality of cushion projections are made of the same resin material as the resin material constituting the volume raising portion.

Accordingly, in addition to the effects of the first or second examples, the following effects can be further obtained. That is, the leg portion does not directly abut on the end surface of the circumferential edge of the window pane, but the cushion projections made of the soft material abut on the end surface of the circumferential edge of the window pane. Therefore, the damage of the window pane and the generation of abnormal noise can be prevented.

(4) In a fourth example, there is provided the molding for a vehicle according to any one of the first to third examples, wherein a portion of the foot portion, which abuts on the window pane or a vehicle body panel when the molding is attached to the window pane, is formed with a cushion abutting portion, which is made of a resin material softer than a resin material constituting the foot portion other than the cushion abutting portion.

Accordingly, in addition to the effects of any one of the first to third examples of the invention, the following effects can be further obtained. That is, since the cushion abutting portion made of the soft material is formed at the portion of the foot portion that abuts on the window pane or a vehicle body panel, the generation of abnormal noise can be prevented.

(5) In a fifth example, there is provided a method for manufacturing the molding for a vehicle according to the first example, the method including: performing primary molding by injection-molding a primary molded product including at least the head portion of the main body of the molding; and performing secondary molding by arranging the primary molded product as an insert in a forming mold and injection-molding the volume raising portion to the primary molded product by using the resin material softer than the resin material constituting the head portion.

Accordingly, the following effects similar to the effects of the first example can be obtained. That is, according to the method of the invention, the main body including the head portion is injection-molded to mold the primary molded product in advance. Thereafter, the volume raising portion can be injection-molded to the primary molded product on the back side of the head portion to obtain the secondary molded product (finished product). Therefore, even if the molten resin constituting the volume raising portion in the secondary molding process has shown a difference in shrinkage amount according to a difference in thickness of the volume raising portion, the influence of sink caused by the secondary molding process is merely actualized on the back surface of the head portion at the utmost, and the front surface of the head portion (that is, the decorative face) that is already finished in the primary molding process is not influenced at all. Since the injection molding is divided into the two processes (separate processes) on the surface side and back side of the head portion in this way, there is no concern that the external appearance of the decorative face may be impaired even if the volume raising portion is additionally formed in order to realize variant cross-sections in the longitudinal direction.