Sun shade apparatus

A sun shade apparatus of the present invention has a curtain capable of shielding a window portion of a door. The curtain can be stretched between a shielding state and an open state on the window portion. The apparatus has a motor, a cable provided so as to be capable of being forced out or drawn in by the operation of the motor, and a connector connecting the cable and the curtain to each other. The curtain is stretched with the operation for forcing out or drawing in the cable. The connector has a connection release mechanism that releases the cable and the curtain from the state of being connected when a load equal to or higher than a predetermined value is applied against the operation for forcing out or drawing in the cable.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from Japanese Patent Application No. 2006-218098 filed Aug. 10 2006. The entire contents of this priority application are incorporated herein by reference.

BACKGROUND OF THE INVENTION

I. Technical Field

The present invention relates to a sun shade apparatus mounted on a vehicle door or the like.

II. Description of Related Art

A motor-driven type of vehicle door sun shade apparatus drives a motor to perform an operation to force out or draw in a cable. With this operation, a curtain connected to the cable is stretched. A window portion of a vehicle door is shielded by stretching the curtain in this way to prevent an increase in temperature in the vehicle compartment and protect [[a]] privacy in the vehicle compartment. See, for example, Japanese Patent Laid-Open Nos. 2003-182358 and 2005-96529.

However, since the curtain stretching operation is performed by driving a motor in such a sun shade apparatus, the cable or the curtain, or a connector for connecting the cable and the curtain or the like may be deformed, for example, when a foreign object is jammed in the curtain stretching direction to impose an excessive load in the direction opposite to the cable forcing-out or drawing-in direction. This may cause a malfunction.

There has been a need to provide a rail for the stretching operation based on use of a cable. If the rail sectional area is increased, for example, as a result of the provision of a safety mechanism (a mechanism for stopping the operation in the event of emergency) or the like for ensuring safety at a position in the course of the cable operation, the area of vision may be so reduced that a safety check may be difficult.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a sun shade apparatus in which a malfunction or the like does not occur even when an excessive load is imposed in the direction opposite to the curtain stretching direction.

A sun shade apparatus of the present invention is characterized by including a motor, a cable provided so as to be capable of being forced out or drawn in by the operation of the motor, a curtain capable of shielding a window portion by being stretched between a shielding state and an open state on the window portion with the operation for forcing out or drawing in the cable, a connector connecting the cable and the curtain to each other, and a connection release mechanism provided in the connector, the connection release mechanism enabling release of the cable and the curtain from a state of being connected by the connector when a load higher than a predetermined value is applied against the operation for forcing out or drawing in the cable.

According to the thus-arranged sun shade apparatus, the connection release mechanism releases the curtain and the cable from the connected state even when a load higher than a predetermined value is applied in the direction opposite to the cable forcing-out or drawing-in direction. In this way, deformation of the cable or the curtain, or the connector is prevented and the sun shade apparatus is enabled to sufficiently perform the functions and to have improved reliability. The load against the cable forcing-out direction or drawing-in operation comprises a load applied to the curtain (e.g., a load applied due to jamming of a foreign object in the direction of movement of the curtain or the like) and a load applied to the connector or the like. In particular, assuming that the connection release mechanism may operate to release the curtain and the cable from the connection when a load is applied to the curtain or the connector, application of the force from the cable to the curtain is thereby stopped to prevent occurrence of a fault such as deformation of the curtain.

In the sun shade apparatus of the present invention, the connector may have a male engaging portion provided on the cable side or on the curtain side and a female engaging portion provided on the curtain side or on the cable side and constituted by an elastic member, and connect the cable and the curtain by engaging the male engaging portion with the female engaging portion. The connection release mechanism may disengage the male engaging portion and the female engaging portion based on elastic deformation of the female engaging portion when the load is applied.

The connection release mechanism based on such engagement between the male engaging portion and female engaging portion is simple in structure and capable of easily releasing the curtain and the cable from the connection or restoring the connection based on elastic deformation of the female engaging portion, and enables the sun shade apparatus to easily repeat performing its function.

The female engaging portion may have a recess formed by a plate spring and the male engaging portion may have a projection. The connection release mechanism may fit the projection and the recess to each other during normal operation and release the projection and the recess from the fitted state by elastic deformation of the recess to disengage the male engaging portion and the female engaging portion in the event of abnormality under application of the load.

The thus-arranged connection release mechanism has the female engaging portion formed so as to have a recess formed by a plate spring and performs release from the connection based on elastic deformation of the recess formed by the plate spring. Therefore, the construction can be simplified and a reduction in size of the female engaging portion and, hence, a reduction in size of the connector can be achieved. Consequently, for example, in a case where a rail or the like for sliding of the connector along the movement of the cable, the width of the rail can be reduced to ensure the maintenance of the field of view and an improvement in the appearance design. Also, the range of use of the connection release mechanism can be increased by suitably selecting the spring constant of the plate spring. For example, if a plate spring having a predetermined spring constant according to the weight of the curtain, the size of the window portion and other factors is selected, the sun shade apparatus can be applied to various uses.

The female engaging portion may have the recess provided between at least two projections formed along the direction of forcing out or drawing in the cable.

According to this arrangement, the projection (on the male engaging portion side) is fitted in the recess positioned between the two projections (on the female engaging portion side). In this case, at the time of cable forcing out operation, the projection on the male engaging portion side comes off from one of the projections on the female engaging portion side. At the time of drawing-in operation, the projection on the male engaging portion side comes off from the other of the projections on the female engaging portion side. Disengagement is effected by this coming-off. Thus, release from the connection can be suitably performed in the event of application of the above-mentioned load regardless of the cable moving direction. Moreover, release from the connection can be achieved by using the simple arrangement which only involves arranging projection formed by the plate spring in the direction of the movement of the cable. Therefore the arrangement contributes to a reduction in size of the apparatus as well as to a reduction in cost.

The above-described projection may have a projecting shape with a slanting surface in the direction of forcing out or drawing in the cable.

If the projection of the male engaging portion is formed of such a projecting shape with a slanting surface, application of a large force between the male engaging portion and the female engaging portion at the time of release from the connection can be avoided to achieve a smooth release operation. That is, the recess and the projection can be released from the fitted state in the direction along the slanting surfaces at the time of release from the connection and, therefore, the release operation can be performed smoothly, for example, in comparison with a case where the recess and the projection are vertically fitted to each other. Also, the magnitude (critical value) of the load at which release from the connection is started can be designed through the slanting angle of the slanting surface. For example, release from the connection is performed at a smaller load if the slanting angle of the slanting surface is reduced, and release from the connection is performed at a higher load if the slanting angle is increased.

DETAILED DESCRIPTION OF THE INVENTION

A sun shade apparatus of the present invention will be described with respect to an illustrative aspect thereof with reference to the drawings.

FIG. 1is a front view of a vehicle door having a sun shade apparatus in accordance with the present invention seen from the vehicle interior side. As shown inFIG. 1, a vehicle door23of the present illustrative aspect has a door panel2having side windows2aand2b, and a sun shade apparatus (also called a blind apparatus)1is provided on the inside of the door panel2. The door panel2has the side windows2aand2bin its upper region, the area of which is about half the entire area, and also has a pillar2cand a pillar (division frame)2d.

The pillar2cstands at the vehicle-front-side edge of the door and constitutes a vehicle-front-side window member for the first side window2a. The pillar2dstands between the side windows2aand2band partitions these side windows from each other. The pillar2dconstitutes a vehicle-rear-side window member for the first side window2aand also constitutes a vehicle-front-side window member for the second side window2b. The pillars2cand2dextend substantially parallel to each other to form the first side window2aon the vehicle front side in substantially rectangular form.

On the other hand, the second side window2bon the vehicle rear side is formed in substantially triangular form by being partitioned by the pillar2d. A window glass is mounted in the first side window2aso as to be upwardly/downwardly movable, while a window glass is immovably mounted in the second side window2b. A trim20is mounted in a lower region of the door panel2. The trim20covers substantially the entire region on the vehicle interior side of the door panel2below the side windows2aand2b.

The sun shade apparatus1has a first blind sheet (curtain)10for covering the first side window2aand a second blind sheet (curtain)13for covering the second side window2b, as shown inFIG. 1. The sun shade apparatus1also has a case3provided with a roll-up shaft30for rolling up the first blind sheet10, a case31having a roll-up shaft31afor rolling up the second blind sheet13, and stretching means (6,7) for stretching the first blind sheet10and the second blind sheet13between a shielding state and an open state.

The blind sheets10and13are sheets for shielding light coming into the vehicle compartment (light shielding or attenuating sheets), e.g., mesh sheets or translucent sheets). The blind sheets10and13are stretched along the vehicle-interior-side surfaces of the window glasses mounted in the side windows2aand2bto cover the side windows2aand2b.

A frame11is attached to an upper end edge of the first blind sheet10. The frame11stretches the upper end edge of the first blind sheet10in the vehicle front-rear direction. Sliders12extending in the frontward and rearward directions are provided on the front and rear ends of the frame11.

The sun shade apparatus1has a pair of rails4for guiding and supporting the sliders12. Each rail4extends along the pillar2cor the pillar2dto guide and support the slider12in the upward/downward direction. The rails4are provided at the same position in the height direction as the first side window2a.

The stretching means for stretching the first blind sheet10is a means for lifting the sliders12along the rails4. The stretching means has two cables6, two cable guides5and one pay-out device7.

Each cable guide5is tubular and a cable6is inserted through the cable guide5. The cable6is a compression-resistant member having, for example, as shown inFIG. 5, a core wire formed of a flexible metal wire or a plastic wire or the like, and a coil spirally wound around the outer periphery of the core wire with a constant pitch. One end of the cable6is attached by means of a connector90(seeFIG. 2) to the slider12provided on the frame11for the first blind sheet10. The cable6is inserted through the rail4and subsequently through the cable guide5. Accordingly, the cable6is guided and supported by and moved along the rail4and the cable guide5to move the slider12along the rail4.

The pay-out device7is provided on an intermediate portion of the cable guide5.

The pay-out device7has a gear box70having a gear, and a motor71. The gear is of such a construction (not shown) as to mesh with the coil of the cable6, and is rotated by the drive force of the motor71. The cable6is paid out by the rotation of the gear. The cable6is thereby moved to lift the slider12while being guided by the cable guide5and the rail4.

The two cable guides5are connected to the pay-out device7. The two cables6inserted through the two cable guides5respectively are simultaneously paid out by the one pay-out device7. Consequently, the two cables6lift a pair of sliders12in synchronization with each other.

A frame14is attached to a stretching end edge of the second blind sheet13. A slider15which projects downward is attached to a lower end of the frame14.

The sun shade apparatus1also has a rail42for guiding and supporting the slider15. The rail42is provided below the second side window2band extends in the vehicle front-rear direction along the lower end of the second side window2b. The rail42is disposed between the door panel2and the trim20.

The stretching means for stretching the blind sheet13is a means for pushing the slider15toward the rear of the vehicle along the rail42. The stretching means for stretching the blind sheet13includes a cable60, a cable guide50and the pay-out device7for paying out the cable60. The pay-out device7has a gear box70and a motor71. The cable60is connected to the slider15and is inserted through the rail42and the cable guide50.

On the other hand, the roll-up shaft30is provided in the case3and is axially supported by the case3. A lower end edge of the first blind sheet10is attached to the roll-up shaft30. The roll-up shaft30is rotated about its axis to roll up the first blind sheet10. A coil spring (not shown) is provided between the roll-up shaft30and the case3to urge the roll-up shaft30. More specifically, the coil spring urges the roll-up shaft30in the direction of rolling up the first blind sheet10. Accordingly, the roll-up shaft30rolls up the first blind sheet10by the urging force of the coil spring. The roll-up shaft31ais axially supported in the other case31. The roll-up shaft31arolls up the second blind sheet13by using the urging force of a coil spring provided between the roll-up shaft31aand the case31.

Next, an essential portion of the sun shade apparatus1will be described in detail.

FIGS. 2 to 4are sectional views taken along line A-A inFIG. 1to illustrate the cable6stretching operation of the sun shade apparatus1and the connection aspect between the cable6and the slider12of the first blind sheet10(seeFIG. 1).FIG. 2is a diagram showing a situation where the first blind sheet10is stretched to a shielding state, i.e., a situation where the cable6is in a forced-out (paid-out) state of being forced out from the pay-out device7.FIG. 3is a diagram showing a situation .where the first blind sheet10is retracted into an open state (“open” in this case means the state of the window portion being uncovered from the state of being covered with the sheet), i.e., a situation where the cable6is in a drawn in state of being drawn in by the pay-out device7.FIG. 4is a diagram showing the mechanism when the cable6and the first blind sheet10are released from a connected state. The sliders12are provided on the front-rear direction ends of the frame11and the cables6are respectively connected to the sliders12by the same mechanisms.

As shown inFIG. 1, an end portion of each cable6is connected to the slider12provided on the frame11for the first blind sheet10by means of the connector90. The connector90has a recessed female engaging portion91provided on the first blind sheet10side (i.e., on the slider12side) and a projecting male engaging portion92provided on the cable6side. The male engaging portion92is engaged with the female engaging portion91to connect the cable6and the first blind sheet10. The arrangement may alternatively be such that a female engaging portion is provided on the cable6side; a male engaging portion is provided on the first blind sheet10side; and these engaging portions are engaged with each other to realize connection.

FIG. 5is a schematic sectional view showing details of the connector90.

In the connector90, the female engaging portion91is connected to the slider12as shown inFIG. 5, while having a recessed shape formed of a plate spring elastically deformable. More specifically, the female engaging portion91is constituted by a spring formed into projecting and recessed shapes. More specifically, the female engaging portion91has a recess97provided between two projections95and96formed along the cable6paying out direction, i.e., the cable6forcing-out or drawing-in direction. A gap is provided between the projections95and96of the female engaging portion91and a retaining member100of the female engaging portion91to permit elastic deformation sufficiently.

The material of the male engaging portion92is not particularly specified. For example, in the present illustrative aspect, a member made of a resin material and formed into a projecting shape is used as the male engaging portion92. The male engaging portion92has a projecting shape (projection93) having slanting surfaces98and99in the cable6paying out direction, i.e., the cable6forcing-out or drawing-in direction.

The first blind sheet10and the cable6are connected to each other by the connector90consisting of the above-described male engaging portion92and female engaging portion91to enable the first blind sheet10to stretch with the cable6forcing-out or drawing-in operation. That is, when the cable6is moved in the direction of being forced out direction (paid out) by the operation of the motor71, the first blind sheet10is stretched into the shielding state at which it shields the window portion2a. When the cable6is moved in the direction of being drawn in (drawn back) by the operation of the motor71, the first blind sheet10is retracted into the open state at which it unshields the window portion2aand rolled up around the roll-up shaft30.

The first blind sheet10can be stretched by the above-described stretching means (6,7). In the present illustrative aspect, the connector90is provided with a connection release mechanism which operates in the event of emergency (abnormality), e.g., in the event that a foreign object is jammed on the first blind sheet10(seeFIG. 4). The connection release mechanism in this case is a mechanism for releasing the cable6and the first blind sheet10from the connection in a case where a load is imposed in the direction opposite to the first blind sheet10stretching or drawing-in direction, for example, due to jamming of a human hand or some other foreign object on the first blind sheet10to produce a load equal to or higher than a predetermined value against the cable6forcing-out or drawing-in operation.

More specifically, when a load equal to or higher than a predetermined value is imposed against the cable6forcing-out or drawing-in operation, the female engaging portion91and the male engaging portion92are disengaged from each other based on elastic deformation of the plate spring forming the female engaging portion91, thereby releasing the cable6and the first blind sheet10from the connection. That is, during normal operation without a load equal to or higher than the predetermined value, the cable6and the first blind sheet10are connected to each other by fitting (engagement) between the projection93of the male engaging portion92and the recess97of the female engaging portion91as shown inFIG. 5. In the event of abnormality under a certain load, release from the fitted (engaged) state is effected by elastic deformation of the plate spring forming the recess97of the female engaging portion91to release the cable6and the first blind sheet10from the connection.

Thus, the plate spring of the female engaging portion91functions dominantly in the connection release mechanism. The point in operation as to whether the projection93of the male engaging portion92and the female engaging portion91are disengaged by elastic deformation of the plate spring corresponds to the threshold of starting of the operation of the connection release mechanism.

The connection release mechanism is provided as described above to enable prevention of generation of a fault such as forcibly drawing back the first blind sheet10by the cable6and, hence, prevention of a fault such as deformation of the first blind sheet10, for example, even when a load is applied to the first blind sheet10.

Since in particular the female engaging portion91has the recess97between at least two projections95and96formed along the cable6forcing-out or drawing-in direction, the projection93of the male engaging portion92is fitted in the recess97positioned between the two projections95and96. At the time of cable6forcing out operation, therefore, the projection93of the male engaging portion92comes off from the front (upper) projection95side of the two projections95and96of the female engaging portion91. At the time of drawing-in operation, the projection93of the male engaging portion92comes off from the rear (lower) projection side96. Disengagement is effected by this coming-off. Thus, release from the connection can be suitably performed in the event of application of a load regardless of the cable6moving direction, that is, regardless of the first blind sheet10stretching direction.

Further, since the projection93of the male engaging portion92has the slanting surfaces98and99in the cable6forcing-out or drawing-in direction, application of a large force between the male engaging portion92and the female engaging portion91at the time of release from the connection can be avoided to achieve a smooth release operation.

That is, the recess and projection can be released from the fitted state in the direction along the slanting surfaces98and99at the time of release from the connection and, therefore, the release operation can be performed smoothly. Also, the magnitude (critical value) of the load at which release from the connection is started can be designed through the slanting angle of the slanting surfaces98and99. For example, release from the connection is performed at a smaller load if the slanting angle of the slanting surfaces98and99is reduced, and release from the connection is performed at a higher load if the slanting angle is increased.

FIG. 6is a diagram for explaining the shape of the connector90.

If the width of the female engaging portion91, i.e., the width a of the plate spring is 12; the thickness b of the plate spring is 0 or more; and the amount (height) e of intrusion of the projection93into the recess97of the female engaging portion is 0.7, it is preferable to set the angle d between the slanting surfaces of the projections95and96of the female engaging portion and the slanting surface of the projection93of the male engaging portion92to a value equal to or larger than 67° and equal to or smaller than 85°, that is, to set the slanting angle c of the slanting surface of the projection93to a value equal to or larger than 122° and equal to or smaller than 140° in stabilizing the disengagement operation when the slanting angle f of the slanting surfaces of the projections95and96is about 30°.

Since a plate spring is used as the connection release mechanism of the connector90in the sun shade apparatus1of the present illustrative aspect, a reduction in size of the apparatus can be achieved in comparison with a case where a spring member or the like is used. Also, since the lap between the recess and projection of the female engaging portion91and the male engaging portion92changes depending on the width of the rail4in particular, the magnitude of the load for release from the connection can be set to a predetermined value (target value) by suitably changing the height of the plate spring. This means that the arrangement of the sun shade apparatus1of the present illustrative aspect can be applied to a wide range of use with respect to various window portions.

The present invention is not limited to the above-described illustrative aspect. Other illustrative aspects described below are also conceivable.

(1) While in the above-described illustrative aspect the connector90connects the first blind sheet10and the cable6by means of the sliders12provided on the frame11for the first blind sheet10, the arrangement may alternatively be such that the first blind sheet10and the cable6are directly connected to each other.

(2) While the connection release mechanism is provided on the first side window2aside in the above-described illustrative aspect, the connection release mechanism can also be provided on the second side window2bside. That is, a connector for connecting the second blind sheet13and the cable60by means of the slider15provided on the frame14for the second blind sheet13may be provided and this connector may be provided with the above-described connection release mechanism.

(3) While the sun shade apparatus1is provided on the window portions of the vehicle door23in the above-described illustrative aspect, the sun shade apparatus1according to the present invention can be applied to house windows as well as to vehicle windows.