Weather strip for automobile

The weather strip for an automobile includes an extrusion formed portion and a molding formed portion and each includes an attaching base portion and a sealing portion. The attaching base portion includes an attaching base portion bottom side portion which faces the outer peripheral portion of the opening and closing member for the opening of the vehicle body or the outer peripheral brim of the opening. A core removing slit is formed at the attaching base portion bottom side portion extending in a longitudinal direction and a connecting sheet provided for covering an outer surface of the attaching base portion bottom side portion by crossing over the core removing slit, The connecting sheet is formed by an olefin system resin and a surface of the connecting sheet facing the attaching base portion bottom side portion is fusion-bonded to the outer surface of the attaching base portion bottom side portion.

This application claims priority under 35 U.S.C. 119 with respect to Japanese Application No. 2017-114191 filed in Japan on Jun. 9, 2017, the entire content of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates to a weather strip for an automobile which seals a portion between the peripheral brim of an opening of the vehicle body of an automobile and an opening and closing member for the opening of the vehicle body.

Description of Related Art

Usually, sealing between the peripheral brim of the opening of the vehicle body of the automobile and the opening and closing member for the opening of the vehicle body, for example, sealing between the peripheral brim of the opening of the vehicle body and the door panel1and the door frame2is made as shown inFIG. 7, by the door weather strip110which is attached to the outer peripheral portion between the door panel1and the door frame2and/or an opening trim weather strip which is attached to the flange portion of the peripheral brim of the opening of the vehicle body. It is noted that the sealing between the door glass5and the door frame2is made by the glass run which is attached to the inner peripheral channel provided at the door frame2.

The door weather strip110which is attached to the outer peripheral portion between the door frame2and the door panel1is formed by an attaching base portion120and a sealing portion formed integrally at the upper portion of the attaching base portion120, as shown inFIG. 14and the sealing portion is formed by a hollow sealing portion130and a sealing lip portion140. The attaching base portion120is fitted into a retainer attached to the outer peripheral portion of the door panel1and the door frame2to be fixed thereto.

Further, there may be a case that the door weather strip110has different cross sectional shapes between a portion which is installed in the door frame2and a portion which is installed in the door panel1. In such case, as shown inFIG. 6, the door weather strip110may be provided with a connecting portion115formed by molding in the vicinity of joint portion between the door frame2and the door panel1. Further, the weather strip110is provided with a molding formed portion110bformed by molding at the corner of the door frame2for bending the corner portion112for connection.

An extrusion formed portion110aof the door weather strip110is provided with an attaching base portion hollow portion122which is formed in a hollow shape in order to improve the flexibility of the hollow sealing portion130and the attaching base portion120and to achieve reduction of weight. Further, a hollow sealing bridge portion125is provided between the hollow sealing portion130and the attaching base portion hollow portion122where the peripheral brim of the opening of the vehicle body is brought into contact to connect the end portions of the outer wall portion of the hollow sealing portion130.

However, when using thus formed molding formed portion110b, in order to form a hollow portion in the hollow sealing portion130, it is necessary to provide a core member in the molding die and after molding forming it is further necessary to remove the core member from a core removing slit124provided in the attaching base portion120of the molding formed portion110b.

For this reason, as shown inFIG. 14, in order to remove the core member, the core removing slit124is formed on the molding formed portion110band the core removing slit124is formed up to around a connecting surface118between the extrusion formed portion110aand the molding formed portion110b.

In order to keep the outer profile (shape) of the molding formed portion110b, it is necessary to fix the core removing slit124not to generate mouth-opening.

Such fixing of the core removing slit124is made by using instant adhesion agent or the like. However, since a liquid type agent is usually used for the instant adhesion agent, it is necessary to carefully handle such liquid agent. Sometimes such liquid instant adhesion agent may protrude from the slit124or may adhered on to an ornamental surface of the door weather strip110and a sealing surface thereof, which may lead to a generation of failure. Further, since a very few amounts of the instant adhesion agent is handled in the adhesion work, a deviation of adhesive force of the core removing slit124may be generated.

Further, as a fixing method for fixing the core removing slit124, a connecting pin is used for covering the slit using a driving tool (See an example in the Patent Document 1). In this method, it was necessary to use the driving tool and workability was not good.

Still further, as shown inFIG. 14, an attaching plate150is used for covering the slit124(See an example in the Patent Document 2). According to the fixing of the attaching plate150, the fixing pin151of the attaching plate150is inserted into the fixing bore of the attaching base portion120. However, in this method, it takes relatively a long time for the work to attach the fixing pin151of the attaching plate150into the fixing bore of the attaching base portion120.

DOCUMENT LIST OF RELATED ART

Patent Document

Patent Document 1: JP2012-116338 A

Patent Document 2: JP2002-337551 A

DISCLOSURE OF INVENTION

The invention was made to solve the above drawbacks of the conventional technologies, and the object of the invention is to provide a weather strip for an automobile which can prevent a core removing slit of an attaching base portion from mouth-opening and at the same time which can be easily manufactured.

In order to solve the above problems, according to a first aspect of the invention, the weather strip for an automobile which seals a portion between a peripheral brim of an opening of the vehicle body of the automobile and an opening and closing member for the opening of the vehicle body includes an extrusion formed portion and a molding formed portion which connects each end portion of the extrusion formed portion, wherein the extrusion formed portion and the molding formed portion respectively include an attaching base portion attached to an outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body and a sealing portion formed integrally with the attaching base portion for sealing between the peripheral brim of an opening of the vehicle body and the opening and closing member for the opening of the vehicle body by being in contact with the peripheral brim of the opening of the vehicle body or the outer peripheral portion of the opening and closing member for the opening of the vehicle body, the attaching base portion having an attaching base portion bottom side portion with plate-like shape which faces the outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body, and wherein the weather strip is characterized in that a core removing slit is formed at the attaching base portion bottom side portion of the molding formed portion extending in a longitudinal direction of the weather strip and a connecting sheet is provided which covers an outer surface of the attaching base portion bottom side portion by crossing over the core removing slit and the connecting sheet is formed by an olefin resin and at the same time a surface of the connecting sheet facing the attaching base portion bottom side portion is fusion-bonded to an outer surface of the attaching base portion bottom side portion.

According to the first aspect of the invention, the weather strip for an automobile which seals a portion between the peripheral brim of the opening of the vehicle body of the automobile and the opening and closing member for the opening of the vehicle body includes an extrusion formed portion and a molding formed portion which connects each end portion of the extrusion formed portion, wherein the extrusion formed portion and the molding formed portion respectively include an attaching base portion attached to an outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body and a sealing portion which is formed integrally with the attaching base portion for sealing the portion between the peripheral brim of an opening of the vehicle body and the opening and closing member for the opening of the vehicle body by being in contact with the peripheral brim of the opening of the vehicle body or the outer peripheral portion of the opening and closing member for the opening of the vehicle body. The attaching base portion has a plate shape attaching base portion bottom side portion which faces the outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body.

Accordingly, the extrusion formed portion is quickly formed by extrusion forming and is connected to the molding formed portion which is formed by molding. Thus, the shape of the weather strip can be formed to agree to the shape of the corner portion of the opening and closing member for the opening of the vehicle body or the shape of the corner portion of the peripheral brim of the opening of the vehicle body. Since the sealing portion is held at the outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body, the position of the sealing member is kept stable and is surely brought into contact with either the peripheral brim of the opening of the vehicle body or the outer peripheral portion of the opening and closing member for the opening of the vehicle body to assure the sealing performance thereof.

Since attaching base portion bottom side portion with plate-like shape the outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body is provided, the outer peripheral portion of the opening and closing member for the opening of the vehicle body or the peripheral brim of the opening of the vehicle body is closely brought into contact with the attaching base portion bottom side portion thereby to attach the attaching base portion in a stable manner.

Since the core removing slit is formed at the attaching base portion bottom side portion of the molding formed portion and the slit extends in a longitudinal direction of the weather strip, the core member can be easily removed from the core removing slit after mold forming.

Further, since the connecting sheet is provided which covers the outer surface of the attaching base portion bottom side portion by crossing over the core removing slit, a mouth-opening of the core removing slit can be prevented by the connecting sheet.

Since the connecting sheet is formed by an olefin resin and at the same time a surface of the connecting sheet facing the attaching base portion bottom side portion is fusion-bonded to the outer surface of the attaching base portion bottom side portion, the connecting sheet can be firmly attached on to the outer surface of the attaching base portion. Further, since the connecting sheet is fusion-bonded to the attaching base portion bottom side portion, by simply pushing the connecting sheet by ultrasonic fusion machine or the like, the fusion bonding can be easily performed to make the attaching process of the connecting sheet to be simplified thereby to improve the attaching work efficiency.

The invention of a second aspect includes the weather strip which is formed with a plurality of uneven portions on the outer surface of the connecting sheet.

According to the second aspect of the invention, the plurality of uneven portions is formed on the outer surface of the connecting sheet by forming a plurality of grooves on the pushing surface of the tip end of the ultrasonic vibrator in advance to bite into the connecting sheet upon welding thereby to surely hold the connecting sheet for effectively transmitting vibrations upon ultrasonic welding of the connecting sheet and the attaching base portion bottom side portion. Thus, the connecting sheet and the outer surface of the attaching base portion bottom side portion can be firmly fusion-bonded.

The invention of a third aspect includes the weather strip wherein the plurality of uneven portions on the outer surface of the connecting sheet is formed in a lattice shape.

According to the third aspect of the invention, a lattice shaped plurality of uneven portions is formed on the outer surface of the connecting sheet by forming a lattice shaped plurality of grooves on the pushing surface of the tip end of the ultrasonic vibrator in advance to bite into the connecting sheet upon welding thereby to surely hold the connecting sheet for effectively transmitting vibrations upon ultrasonic welding of the connecting sheet and the attaching base portion bottom side portion. Thus, the connecting sheet and the outer surface of the attaching base portion bottom side portion can be firmly fusion-bonded.

The invention of a fourth aspect includes the weather strip which is formed with an attaching base portion bottom side portion recessed portion formed on the outer surface of the attaching base portion bottom side portion for accommodating the connecting sheet therein.

According to the fourth aspect of the invention, since the attaching base portion bottom side portion recessed portion is formed on the outer surface of the attaching base portion bottom side portion for accommodating the connecting sheet therein, the connecting sheet can be surely fusion-bonded to a predetermined position of the outer surface of the attaching base portion bottom side portion. The expanding of the connecting sheet out of the outer surface of the attaching base portion bottom side portion can be minimized to surely assure the sealing performance between the outer surface of the attaching base portion bottom side portion and the peripheral brim of the opening of the vehicle body or the opening and closing member for the opening of the vehicle body.

The invention of a fifth aspect includes the weather strip which is formed with the connecting sheet formed by a plurality of rectangular strips which covers the core removing slit.

According to the fifth aspect of the invention, the connecting sheets is formed by the plurality of rectangular strips which covers the core removing slit. Since the molding formed portion itself is set in a range small as possible, the length of the core removing slit becomes not long in response to the length of the molding formed portion and accordingly, even the plurality of rectangular strips is used for forming the connecting sheet, the mouth-opening of the slit can be sufficiently prevented. Further, when a plurality of rectangular strips is used for forming the connecting sheet, a smaller ultrasonic vibrator can be used. Further, the plurality of smaller rectangular strips used for the connecting sheet has a high versatility and accordingly has a high efficiency.

The invention of a sixth aspect includes the weather strip which is formed with the connecting sheet fusion-bonded to the outer surface of the attaching base portion bottom side portion and provided consecutively in a width direction of both sides of the attaching base portion bottom side portion, crossing over the core removing slit.

According to the sixth aspect of the invention, the connecting sheet is fusion-bonded to the outer surface of the attaching base portion bottom side portion provided consecutively in a width direction of both sides of the attaching base portion bottom side portion, crossing over the core removing slit. Therefore, the attaching base portion bottom side portion fusion-bonded under the core removing slit being closed is consecutively fusion-bonded such that the core removing slit and the attaching base portion bottom side portion at both sides are consecutively bonded not to make any step on the outer surfaces of the attaching base portion bottom side portion at both sides. Thus, the sealing performance can be improved without causing any interruption. Further, since the fusion-bonding is made on only the central portion of the connecting sheet, preparation of any specific shape ultrasonic vibrator is not necessary, and the fusion-bonding workability can be improved to surely prevent the core removing slit from an undesired opening.

The invention of a seventh aspect includes the weather strip wherein the fusion-bonding portion of the attaching base portion bottom side portion to which the connection sheet is fusion-bonded is in a shape of a flat surface.

According to the seventh aspect of the invention, since the fusion-bonding portion between the connecting sheet and the outer surface of the attaching base portion bottom side portion is in a shape of flat surface, the connecting sheet can be consecutively closely bonded to the outer surface of the attaching base portion bottom side portion and a pushing force can be applied evenly on the connecting sheet upon fusion bonding. Thus, the connecting sheet and the outer surface of the attaching base portion bottom side portion can be surely fusion-bonded.

The invention of an eighth aspect includes the weather strip wherein the reinforcement ribs are formed at an inner surface of the core removing slit of the attaching base bottom side portion at both sides.

According to the eighth aspect of the invention, since the reinforcement ribs are formed at the inner surface of the core removing slit of the attaching base bottom side portion at both sides, the attaching base portion bottom side portion can be supported by the reinforcement ribs when the connecting sheet is pushed on the outer surface of the attaching base portion bottom side portion to be in closely contact therewith. Thus, any deformation of the attaching base portion bottom side portion can be minimized, and the connecting sheet and the outer surface of the attaching base portion bottom side portion can be surely fusion-bonded.

The invention of a ninth aspect includes the weather strip wherein an opening surface of the core removing slit of the attaching base portion bottom side portion includes an engaging portion having an uneven surface or a stepped surface.

According to the ninth aspect of the invention, since the opening surface of the core removing slit of the attaching base portion bottom side portion includes the engaging portion having the uneven surface or the stepped surface, the opening surface of the core removing slit at both sides is not deviated when the connecting sheet is attached to the outer surface of the attaching base portion bottom side portion and the connecting sheet and the outer surface of the attaching base portion bottom side portion can be surely fusion-bonded.

The invention of a tenth aspect includes the weather strip wherein the connecting sheet is formed by a polyethylene and the weather strip is formed by an EPDM rubber material.

According to the tenth aspect of the invention, since the connecting sheet is formed by a polyethylene and the weather strip is formed by an EPDM rubber material, both the connecting sheet and the attaching base portion bottom side portion are formed by the same olefin system materials and accordingly, both are mutually easily fused to firmly fusion-bond the connecting sheet and the attaching base portion bottom side portion.

Effect of Invention

Since the connecting sheet is provided which covers the outer surface of the attaching base portion bottom side portion crossing over the core removing slit, a mouth-opening of the core removing slit can be prevented.

Further, since the connecting sheet is formed by the olefin system resin material and at the same time the surface of the connecting sheet facing the attaching base portion bottom side portion is fusion-bonded to the outer surface of the attaching base portion bottom side portion, the connecting sheet can be firmly fixed to the outer surface of the attaching base portion bottom side portion and at the same time both can be easily bonded by using a ultrasonic fusion bonding machine to easily achieve the attaching work of the connecting sheet to thereby improve the efficiency of attaching work.

The preferred embodiments of the door weather strip10according to one embodiment of the invention will be explained hereinafter with reference toFIGS. 1 through 13of the attached drawings. The door weather strip according to the embodiment can be used widely for any type of the weather strip other than the door weather strip, such as an opening weather strip which is attached to the peripheral brim6of the opening of the vehicle body, a luggage door weather strip which is attached to the luggage door, or a glass run, etc.

FIG. 7shows a side view of an automobile to which the door weather strip10according to the invention is installed.FIG. 6is a view showing the entire front side of the door weather strip10. to be installed to the door panel1and the door frame2.FIG. 1shows the bottom plan view of the later described attaching base portion20of the vertical side connecting portion15.FIG. 2shows a bottom plan view of the later described attaching base portion20of the corner portion12andFIG. 3shows a cross section view taken along the line A-A inFIG. 1

The door weather strip10is installed at the outer peripheral portion of the automobile door which is formed by the door panel1and the door frame2. According to the embodiment, the door weather strip10to be installed at the rear door will be explained, however the invention can be applicable to the door weather strip10to be installed at the front door.

The door weather strip10is formed by an extrusion formed portion10awhich is formed by extrusion and a molding formed portion10bwhich is formed by molding to form the corner portion12and the vertical side portion15connecting the end portions of each extrusion formed portion10a.

As shown inFIG. 6, the extrusion formed portion10ais formed by the upper side portion13which is attached to the upper side of the door frame2, the vertical side upper portions14which are attached to the vertical side portion of the door frame2at front side and rear side thereof respectively, the vertical side lower portions16,16which are attached to the vertical sides of the outer peripheral portion of the door panel1at front side and rear side thereof and a lower side portion17which is attached to the lower side of the door panel1. The lower side portion17can be integrally molded consecutively with the vertical side lower portions16,16by extrusion. It is noted that the lower side portion17can be omitted, by forming only the vertical side power portions16,16.

As shown inFIG. 1, the vertical side upper portion14and the vertical side lower portion16are formed by the attaching base portion20and the hollow sealing portion30and the sealing lip40integrally formed from the attaching base portion20.

The attaching base bottom side portion21is formed at the lower side of the attaching base portion20. The attaching base sealing projections27are formed at both side ends of the attaching base portion bottom side portion21to assure the sealing performance between the door frame2and the attaching base portion20.

The attaching base portion hollow portion22is formed inside of the attaching base portion20of the vertical side upper portion14and the vertical side lower portion16adjacent to the hollow sealing portion30This can increase the flexibility of the attaching base portion20and makes the door weather strip10to be easily bendable for installing along the door frame2and the door panel1to further decrease the weight.

The sealing bridge portion25is formed between the hollow sealing portion30and the attaching base portion hollow portion22at the extrusion formed portion10ato improve the rigidity of the hollow sealing portion30and at the same time to prevent from abnormal deformation thereof. Thus, the sealing performance at the hollow sealing portion30can be improved. However, as will be explained later, the hollow sealing bridge portion25is not provided in the attaching base portion20of the vertical side connecting portion15which forms the molding formed portion10b. This is because the core member in the molding mold has to be removed therefrom.

The molding formed portion10bis attached to the joint portion with the corner of the door frame2and is formed by the corner portions12,12which connect the upper side portion13and the vertical side upper portion14and the vertical side connecting portion15which connects the vertical side upper portion14and the vertical side lower portion16at the joint portion between the rear side of the door frame2and the door panel1. It is noted that the vertical side connecting portion15may be provided at the joint portion between the front side of the door frame2and the door panel1. However, in this embodiment, the vertical side connecting portion15is not provided and instead, the vertical side upper portion14and the vertical side lower portion16are consecutively formed integrally.

It is noted here that the extrusion formed portion10aand the molding formed portion10brespectively include the attaching base portion20and the hollow sealing portion30as will be explained later. The cross section of the molding formed portion10bgradually changes the shape thereof from one end to the other end, when the molding formed portion10bis connected with the extrusion formed portion10awith different cross section in shape from that of the molding formed portion10b.

An embodiment of the invention regarding to the vertical side connecting portion15will be explained. As an example, the vertical side connecting portion15which connects the vertical side upper portion14and the vertical side lower portion16at the joint portion between the rear side of the door panel1and the door frame2of the door weather strip10at the rear door. The molding formed portion10battached to the front side connecting portion or to the front side door is formed similarly. As shown inFIG. 1, at the connecting part connecting the vertical side upper portion14and the vertical side connecting portion15, the upper portion connecting surface18is provided and the lower portion connecting surface19is provided at the connecting portion connecting the vertical side lower portion16and the vertical side connecting portion15. The explanation on the corner portion12will be made later on.

Approximately the central portion of the vertical side connecting portion15, i.e., the shape of a part along the line A-A inFIG. 1will be explained hereinafter. The vertical side connecting portion15of the door weather strip10is formed by the attaching base portion20which is attached to the door panel1and the hollow sealing portion30which is formed integrally with the attaching base portion20and is brought into contact with the peripheral brim6of the opening of the vehicle body.

The hollow sealing portion30is provided with a sealing lip40which is brought into contact with the door panel1or the door frame2. The hollow sealing portion30seals a portion between the door panel1or the door frame2and the peripheral brim6of the opening of the vehicle body and the sealing lip portion40seals a portion between the door panel1or the door frame2and the door weather strip10.

The bottom side of the attaching base portion20is formed with a plate shaped attaching base portion bottom side portion21and at each end of each side thereof, the attaching base portion side end23,23is formed. The attaching base portion side ends23,23are supported by the channels or the like formed by bending a sheet metal of the door panel1. The attaching base portion sealing projections27,27are formed on the surfaces of the attaching base side ends23,23at both sides which are to be in contact with the door panel1. The attaching base portion sealing projections27,27are formed extending in a longitudinal direction.

The attaching base portion sealing projections27,27seal the portion between the door panel1and the attaching base portion20. By providing the attaching base portion sealing projections27,27at both sides on the outer surface of the attaching base portion bottom side portion21, an entering of foreign object or a rain water from the gap between the attaching base portion20of the door weather strip10and the outer peripheral portion of the door can be prevented over a wide range of the outer periphery of the door.

The core removing slit24is formed at the attaching base portion bottom side portion21for removing the core member in the molding to mold the hollow sealing portion30upon mold forming process. The core removing slit24continues to the inside of the hollow sealing portion30. In other words, since the hollow sealing bridge portion25is not provided, the attaching base portion hollow portion22and the inside of the hollow sealing portion30are formed integrally and accordingly, the core member which has formed the hollow sealing portion30can be removed from the core removing slit24.

As shown inFIG. 1, the attaching base portion bottom side portion21is formed as a flat surface. The core removing slit24is formed from the upper connecting surface18which is connected with the vertical side upper portion14to the vicinity of the lower connecting surface19which is connected to the vertical side lower portion16in a longitudinal direction. According to the embodiment shown inFIG. 1, the core removing slit24is formed in a straight line, however, the slit24may be formed in a zig zag shape along the attaching base portion bottom side portion21.

The connecting sheet50which covers the outer surface of the attaching base portion bottom side portion21, crossing over the core removing slit24. The connecting sheet50is fusion-bonded to the outer surface of the attaching base portion bottom side portion21. The connecting sheet50is formed by olefin system synthetic resin material and the door weather strip10including the attaching base portion bottom side portion21is formed by EPDM (ethylene-propylene-diene) rubber materials. Both of these two materials are formed by the olefin system material by which the surface of the connecting sheet50facing the attaching base portion bottom side portion21and the outer surface of the attaching base portion bottom side portion21can be firmly fusion-bonded together.

By this structure, the connecting sheet50can prevent the core removing slit24from opening by crossing over the core removing slit24. It is noted that the by fusion-bonding the connecting sheet50to the outer surface of the attaching base portion bottom side portion21, both are firmly bonded and since the attachment is made by fusion-bonding only, as will be explained later, the bonding can be performed by using ultrasonic fusion-bonding machine to easily perform the attaching work.

Further, as shown inFIG. 12andFIG. 13, when the connecting sheet50is fusion-bonded, a plurality of uneven portions51and a plurality of convex portions52are formed on the outer surface of the connecting sheet50. According to the embodiment, as will be explained later, the connecting sheet50is pushed by the ultrasonic vibrator60of the ultrasonic fusion-bonding machine to firmly bond the connecting sheet50to the outer surface of the attaching base portion bottom side portion21. Thus, the connecting sheet50can be surely attached to the outer surface of the attaching base portion bottom side portion21by fusion-bonding.

It is preferable to form the fusion-bonding area of the attaching base portion bottom side portion21to which the connecting sheet50is fusion-bonded, to be a flat surface. In such structure, the pushing force is applied evenly on the outer surface of the attaching base portion bottom side portion21to be closely brought into contact with the connecting sheet50and accordingly, the connecting sheet50can be surely pushed by the ultrasonic vibrator60to surely fusion-bond the outer surface of the attaching base portion bottom side portion21to the connecting sheet50.

As shown inFIG. 13, the plurality of uneven portions51on the outer surface of the connecting sheet50is formed as a lattice shape. In this structure, the uneven portions51are formed widely on the surface of the connecting sheet50in the vertical directions and in the lateral directions and each peak of the convex portions52is formed to be a shape of pyramid to firmly and evenly fusion-bonding the connecting sheet50to the outer surface of the attaching base portion bottom side portion21. Thus, the connecting sheet50can be surely attached to the outer surface of the attaching base portion bottom side portion21by fusion-bonding. It is noted that the lattice shape uneven portions51can be easily formed by forming the end surface of the ultrasonic vibrator60of the ultrasonic fusion-bonding machine to be a lattice shape.

As shown inFIGS. 4an5, the attaching base portion bottom side portion recessed portion21amay be formed on the outer surface of the attaching base portion bottom side portion21for accommodating therein the connecting sheet50. In this case, when the connecting sheet50is attached, the connecting sheet50is fitted into the attaching base portion bottom side portion recessed portion21a. Thus, the connecting sheet50can be surely positioned at a predetermined position of the outer surface of the attaching base portion bottom side portion21for fusion-bonding.

Further, by accommodating the connecting sheet50in the attaching base portion bottom side portion recessed portion21a, expanding of the connecting sheet50from the outer surface of the attaching base portion bottom side portion21can be minimized and the connecting sheet50attached to the outer surface of the attaching base portion bottom side portion21does not interfere the peripheral brim6of the opening of the vehicle body or the door frame2which is the opening and closing member for the opening of the vehicle body. Thus, the sealing performance between the outer surface of the attaching base portion bottom side portion21and the peripheral brim6of the opening of the vehicle body or the door frame2can be improved.

As shown inFIG. 1, the connecting sheet50can be formed by a plurality of rectangular strips crossing over the core removing slit24for covering the same. When the connecting sheet50is formed by a plurality of rectangular strips, only the necessary portion of the connecting sheet50may be fusion-bonded along the core removing slit24to improve the efficiency of fusion-bonding work.

Further, the connecting sheet50may be formed by an elongated sheet plate extending along the attaching base portion bottom side portion21in a longitudinal direction. When the connecting sheet50is formed by such elongated sheet plate extending along in a longitudinal direction of the attaching base portion bottom side portion21, the elongated sheet shaped connecting sheet50can be attached to the attaching base portion bottom side portion21and the core removing slit24can be covered over the entire length hereof. This can improve the efficiency of work for arranging the connecting sheet50to the attaching base portion bottom side portion21.

It is preferable to fusion-bond the connecting sheet50to the outer surface of the attaching base portion bottom side portion21consecutively in a width direction in both sides of the attaching base portion bottom side portion21by at least crossing over the core removing slit24. In such case, since the core removing slit24and the outer surface of the attaching base portion bottom side portion21at both sides are consecutively fusion-bonded, generation of deviation between both side outer surfaces of the attaching base portion bottom side portion21can be suppressed and generation of step therebetween can be also suppressed and no cause of degrading the sealing performance is generated to surely prevent the core removing slit24from mouth-opening.

Further, only the center portion of the connecting sheet50is fusion-bonded and no specific ultrasonic vibrator is needed. Thus, the fusion-bonding work can be easily performed to surely prevent the core removing slit24from mouth-opening. It is also preferable that not only the central portion, but also over the entire surface of the connecting sheet50is fusion-bonded to the outer surface of the attaching base portion bottom side portion21.

As shown inFIG. 3, it is preferable to form reinforcement ribs26at the inner surface of both sides of the core removing slit24of the attaching base portion bottom side portion21in the molding formed portion10b. In such case, as will be explained later, by closely attaching the connecting sheet50to be in contact with the outer surface of the attaching base portion bottom side portion21and the attaching base portion bottom side portion21is held by the reinforcement ribs26when pushed to thereby minimize the deformation of the attaching base portion bottom side portion21. Thus, the connecting sheet50can be surely fusion-bonded to the attaching base portion bottom side portion21.

As shown inFIG. 4, the opening surface of the core removing slit24of the attaching base portion bottom side portion21can be formed such that the core removing slit convex portion24aand the core removing slit recessed portion24aface to each other. In such case, the core removing slit convex portion24acan be fitted into the core removing slit recessed portion24anot to have deviation of the opening surface at both sides of the core removing slit24when attaching the connecting sheet50to the outer surface of the attaching base portion bottom side portion21and accordingly, not to generate a step at the outer surface of attaching base portion bottom side portion21. Thus, the connecting sheet50can be surely fusion-bonded to the both sides of the core removing slit24.

Further, as shown inFIG. 5, the opening surface of the core removing slit24of the attaching base portion bottom side portion21can be formed such that the core removing slit stepped portion24dand the core removing slit stepped portion24dengage with each other. In such case, the core removing slit stepped portion24dcan engage with the core removing slit stepped portion24dnot to have deviation of the opening surface at both sides of the core removing slit24when attaching the connecting sheet50to the outer surface of the attaching base portion bottom side portion21and accordingly, not to generate a step at the outer surface of attaching base portion bottom side portion21. Thus, the connecting sheet50can be surely fusion-bonded to the both sides of the core removing slit24.

It is preferable to form the connecting sheet50by a polyethene and to form the door weather strip10entirely, including the attaching base portion20by the EPDM rubber materials. In this case, since the connecting sheet50and the attaching base portion bottom side portion21are formed by olefin system materials and accordingly, the connecting sheet50and the attaching base portion bottom side portion21are firmly fusion-bonded together.

It is noted that the connecting sheet50can be formed by another olefin system synthetic resin material other than polyethylene material. Further it is noted that the door weather strip10may be formed by another olefin system rubber or the olefin system plastic elastomer other than the EPDM rubber.

Next, the embodiment of the corner portion12shown inFIG. 2will be explained. This embodiment indicates the molding formed portion10bat the corner portion12and this embodiment is different from the vertical side connecting portion15of the first embodiment inFIG. 1in the structure that the molding formed portion10bis bent at approximately right angle and formed as the corner portion16. The other structures are the same.

The core removing slit24is provided at the attaching base portion20in the corner portion12and the connecting sheet50is provided, crossing over the core removing slit24. The connecting sheet50is fusion-bonded, covering the outer surface side of the attaching base bottom side portion21. The connecting sheet50can be used as in either the rectangular strip shape or the elongated sheet shape. When the elongated sheet shape connecting sheet50is used, connecting sheet50can be fusion-bonded per every side bent at approximately right angle.

Next, the method for attaching the connecting sheet50to the outer surface of the attaching base bottom side portion21by fusion-bonding will be explained with reference toFIGS. 8 through 13.FIG. 8is a schematic view of a process of fusion-bonding in which the connecting sheet50is fusion-bonded to the attaching base bottom side portion21of the door weather strip10by the ultrasonic vibrator60.

Under the state that the core removing slit24open to the attaching base bottom side portion21is closed, the connecting sheet50is placed on the attaching base bottom side portion21and the ultrasonic vibrator60is pushed down from upper side in a direction indicated with an arrow inFIG. 8to push the connecting sheet50downward. Then, the portion indicated with “A” of the connecting sheet50is welded by the friction heat and fusion-bonded to the attaching base bottom side portion21.

In this process, as shown inFIG. 9, first, the connecting sheet50is placed to cross over the core removing slit24of the attaching base bottom side portion21.

Then, as shown inFIG. 10, the ultrasonic vibrator60is placed on the connecting sheet50. The tip end of the ultrasonic vibrator60is formed with a pushing surface61which pushes the connecting sheet50. According to this embodiment, the pushing surface61is formed in a lattice shape having a sharp top in a shape of pyramid. By forming the pushing surface61to have a shape as explained, the pushing surface61can surely bite into the connecting sheet50to surely hold the connecting sheet50to transmit the vibration to the fusion-bonding surface.

Next, as shown inFIG. 11, the tip end of the ultrasonic vibrator60pushes the connecting sheet50to vibrate the same to thereby fusion-bond the surface of the connecting sheet50facing the attaching base bottom side portion21. Thus, the connecting sheet50is fusion-bonded.

Thereafter, when the ultrasonic vibrator60is separated from the connecting sheet50, the connecting sheet50is fusion-bonded as shown inFIG. 12, and a lattice pattern is transferred to the front surface of the connecting sheet50and the lattice shape uneven portions51with the pyramid shape convex portions52are formed on the surface of the connecting sheet50.

Regarding to the size of the connecting sheet50, the thickness of the sheet with about 0.15 mm is used. In such case, the pushing level of the ultrasonic vibrator60for pushing the connecting sheet50is about the depth of about 0.5 to 1.5 mm. The thickness of the connecting sheet50at the uneven portion51is about 40 to 60 μm and the strength thereof is sufficient to prevent the mouth-opening of the core removing slit24.

FIG. 13shows the plan view of the part of the connecting sheet50and the uneven portion51is formed on the front surface of the connecting sheet50in a lattice shape and the convex portion52is formed in a shape of pyramid to generate the lattice shape. The uneven portion51is strongly pushed to the attaching base portion bottom side portion21to firmly fusion-bond. It is noted that as shown inFIG. 13, it is preferable to at least fusion-bond a part of the connecting sheet side end53which is the end portion of the connecting sheet50, crossing over the core removing slit24.

In the drawings:10: door weather strip10b: molding formed portion,20: attaching base portion,21: attaching base portion bottom side portion,24: core removing slit,50: connecting sheet,60: ultrasonic vibrator