Abstract:
A register includes an operation knob which is slidably assembled to a selected one of front horizontal blades and which is connected to a selected one of rear vertical blades via a connection mechanism. The connection mechanism includes a connection pillar portion formed integrally with an intermediate portion of the selected vertical blade, the connection pillar portion having a generally circular cross section and being located at a position deviating from a rotation axis of the selected rear vertical blade, and a pair of connection arm portions extending rearward from the rear end of the operation knob with a predetermined space formed therebetween. The operation knob is connected to the selected vertical blade in a state where the connection pillar portion is rotatably inserted into an engagement groove between the connection arm portions.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to an air outlet device for a vehicle cabin (hereinafter referred to as “vehicle-cabin air outlet device”), such as a center register, a side register, a lower register, or a side defroster. 
         [0003]    2. Description of the Related Art 
         [0004]    Conventionally, there exists a vehicle-cabin air outlet device of a type which includes a rectangular tubular body which forms an air guide passage; a plurality of front-side parallel wind-direction adjustment plates rotatably supported inside the tubular body at a front end thereof; a plurality of rear-side parallel wind-direction adjustment plates which are perpendicular to the front-side wind-direction adjustment plates and rotatably supported inside the tubular body at a position shifted rearward from the front end by a predetermined distance; and an operation knob which is assembled to a selected one of the front-side wind-direction adjustment plates to be slidable along a longitudinal direction thereof. The operation knob is operatively connected to a selected one of the rear-side wind-direction adjustment plates via a connection mechanism. When the operation knob is slid on the selected front-side wind-direction adjustment plate along the longitudinal direction, the rear-side wind-direction adjustment plates are swung in a mutually interlocked manner. 
         [0005]    The tubular body, the front-side wind-direction adjustment plates, and the rear-side wind-direction adjustment plates of a vehicle-cabin air outlet device of such a type are resin molded products formed from a synthetic resin material. In general, these constituent members are separately molded, and the vehicle-cabin air outlet device is assembled through an assembling operation of mounting the front-side and rear-side wind-direction adjustment plates to the tubular body one after another. Therefore, because of a larger number of parts, the assembly of the vehicle-cabin air outlet device requires a large number of assembly steps, which makes the assembly work troublesome. 
         [0006]    Recently, in order to cope with the above-described drawback, there has been proposed a molding method. In this method, the rear-side wind-direction adjustment plates or the front-side wind-direction adjustment plates are molded as a group. Also, in this method, a connection rod for connecting the rear-side wind-direction adjustment plates or the front-side wind-direction adjustment plates each other and/or a support plate for rotatably supporting the rear-side wind-direction adjustment plates or the front-side wind-direction adjustment plates is molded with the group within the same molding die, and the molded rear-side wind-direction adjustment plates or front-side wind-direction adjustment plates are assembled to the connection rod and/or the support plate (see Japanese Patent Publication (kokoku) No. H4-69542). This molding method has already being put into practical use, and there has been proposed a vehicle-cabin air outlet device which is referred to as a “register” and which is configured by making use of the above-mentioned molding method (see Japanese Patent No. 3329670). In manufacture of the register proposed in the latter Japanese Patent, a plurality of vertical blades, which correspond to the rear-side wind-direction adjustment plates, and a retainer, which corresponds to the tubular body, are molded in the same molding die, and the vertical blades are assembled into the retainer within the molding die. 
         [0007]    Incidentally, in an air outlet device of such a type, an operation knob, which is assembled to a selected one of front-side wind-direction adjustment plates to be slidable along a longitudinal direction thereof, is operatively connected to a selected one of rear-side wind-direction adjustment plates via a connection mechanism; and when the operation knob is slid on the selected front-side wind-direction adjustment plate along the longitudinal direction, the rear-side wind-direction adjustment plates are swung in a mutually interlocked manner. The complex structure of the connection mechanism may possibly hinder performance of the above-described molding method, and the structure of the connection mechanism may possibly influence the operability of the operation knob. The latter Japanese Patent proposes a connection mechanism which can cope with these problems. 
         [0008]    In the register proposed in the Japanese Patent, the connection mechanism is composed of a first connection mechanism portion provided on a selected one of the rear-side wind-direction adjustment plates, and a second connection mechanism portion provided on the operation knob side.  FIGS. 6 and 7  show the connection mechanism of the register, and  FIG. 8A  schematically shows a state where all the vertical blades are molded within the same molding die. 
         [0009]    The register, which is denoted by reference numeral  10 , includes a retainer  10   a , which is a rectangular tubular body for forming an air guide passage; a horizontal blade group  10   b  composed of a plurality of horizontal blades which are arranged in parallel in the vertical direction and rotatably supported inside the retainer  10   a  at a position near a front end opening thereof; a vertical blade group  10   c  composed of a plurality of vertical blades which are arranged in parallel in the horizontal direction and are rotatably supported inside the retainer  10   a  at a position shifted rearward from the horizontal blade group  10   b  by a predetermined distance; and a connection mechanism  10   d  for operationally connecting an operation knob to the vertical blades. These constituent members are formed of a synthetic resin material. 
         [0010]    The vertical blade group  10   c , a connection rod  13   e  (which will be described later) for connecting the vertical blades of the vertical blade group  10   c  together, and a support plate  13   f  (which will be described later) for rotatably supporting the vertical blades are molded in a molding die  10   e  schematically shown in  FIG. 8A . The molding die  10   e  is configured to enable the vertical blades of the molded vertical blade group  10   c  to be assembled to the connection rod  13   e  and the support plate  13   f  within the molding die  10   e . Notably, in  FIG. 8A , reference numeral  10   e   1  denotes a stationary die half, reference numeral  10   e   2  denotes a movable die half, and reference character PL denotes a parting line at which the movable die half  10   e   2  can be separated from the stationary die half  10   e   1 . 
         [0011]    In the register  10 , as shown in  FIGS. 6 and 7 , an operation knob  12  is assembled to a selected horizontal blade  11  located at a central portion in the horizontal blade group  10   b . The operation knob  12  is assembled to the horizontal blade  11  to be slidable in the horizontal direction (the longitudinal direction). The connection mechanism  10   d  is formed between the operation knob  12  and a selected vertical blade  13  located at a central portion in the vertical blade group  10   c . The connection mechanism  10   d  is composed of a first connection mechanism portion  10   d   1  provided on the vertical blade  13  and a second connection mechanism portion  10   d   2  provided on the operation knob  12  side. 
         [0012]    The first connection mechanism portion  10   d   1  includes upper and lower flat support plate portions  13   a  and  13   b  integrally formed at a front-side intermediate portion of the vertical blade  13 , and left and right connection pillar portions  13   c  and  13   d  having an elliptical cross section and integrally formed at front portions of these support plate portions  13   a  and  13   b  such that the connection pillar portions  13   c  and  13   d  are biased leftward and rightward, respectively. A front-side wall portion of the vertical blade  13  between the support plate portions  13   a  and  13   b  is formed to have a rearward concaved arcuate cutout. Such a structure of the first connection mechanism portion  10   d   1  enables the movable die half  10   e   2  to be separated from the stationary die half  10   e   1  at the parting line PL, serving as a reference line. The vertical blade group  10   c  provided with the first connection mechanism portion  10   d   1  is assembled to the connection rod  13   e  and the support plate  13   f  so as to form an assembly structure, which is assembled into the retainer  10   a.    
         [0013]    Meanwhile, the second connection mechanism portion  10   d   2  is formed integrally with a rear portion of the operation knob  12 , which is assembled to the horizontal blade  11  to be slidable in the horizontal direction. The second connection mechanism portion  10   d   2  includes left and right outside connection arm portions  12   a  and  12   b  projecting rearward with a predetermined horizontal space formed therebetween, and a center connection arm portion  12   c  located between the connection arm portions  12   a  and  12   b  and dividing the space between the connection arm portions  12   a  and  12   b  into left and right engagement grooves  12   a   1  and  12   b   1 . The center connection arm portion  12   c  is slightly shorter than the connection arm portions  12   a  and  12   b , and its projection end portion is formed into a conical shape. 
         [0014]    The first connection mechanism portion  10   d   1  is operationally connected to the second connection mechanism portion  10   d   2  in a state where the connection pillar portions  13   c  and  13   d  are inserted into the corresponding engagement grooves  12   a   1  and  12   b   1  of the second connection mechanism portion  10   d   2 . 
         [0015]    The connection mechanism  10   d  operates as follows. When the operation knob  12  assembled to the horizontal blade  11  is slid leftward or rightward, the operation knob  12  pushes the connection pillar portions  13   c  and  13   d  inserted into the corresponding engagement grooves  12   a   1  and  12   b   1  leftward or rightward to thereby swing the vertical blade  13  leftward or rightward. During this operation, one of the connection pillar portions  13   c  and  13   d  pushed by the center connection arm portion  12   c  moves within the corresponding engagement groove toward the opening portion side. When the vertical blade  13  swings by a predetermined amount, the one of the connection pillar portions  13   c  and  13   d  passes over the tip end of the center connection arm portion  12   c  and moves outside toward one of the connection arm portions  12   a  and  12   b , and the other of the connection pillar portions  13   c  and  13   d  moves toward the base end portion of the corresponding engagement groove, and is pushed by the other of the outside connection arm portions  12   a  and  12   b.    
         [0016]    Incidentally, although the above-described structure of the first connection mechanism portion  10   d   1  of the connection mechanism  10   d  enables the first connection mechanism portion  10   d   1  to be molded integrally with the vertical blade group  10   c  between the stationary die half  10   e   1  and the movable die half  10   e   2  of the molding die  10   e , mutually facing portions of the stationary die half  10   e   1  and the movable die half  10   e   2  have complicated shapes as indicated by the parting line PL. In this structure, since a plurality of narrow projections are present, a problem associated with strength may arise. Therefore, there is a demand for a structure of the connection mechanism  10   d  which simplifies the shape of the parting line PL to thereby improve the strength of the molding die  10   e.    
         [0017]    In the above-described connection mechanism  10   d , while the blades of the vertical blade groups  10   c  are swung in an interlocked manner, pushed one of the connection pillar portions  13   c  and  13   d  of the first connection mechanism portion  10   d   1  is moved from the side of the center connection arm portion  12   c  of the second connection mechanism portion  10   d   2  to one of the connection arm portions  12   a  and  12   b . At that time, the load acting on the operation knob  12  changes suddenly. As a result, a person who operates the operation knob  12  feels a resistance during the operation, which impairs the operation feel. Therefore, the connection mechanism  10   d  is demanded to have a structure which can improve the operation feel of the operation knob  12 . 
         [0018]    Further, since the first connection mechanism portion  10   d   1  of the connection mechanism  10   d  has the above-described structure, a blade portion which functions as a vertical blade is not present between the upper and lower support plate portions  13   a  and  13   b . Therefore, when the vertical blade group  10   c  is swung, a guide passage which causes air to flow straight is formed between the upper and lower support plate portions  13   a  and  13   b , as indicated by alternate long and short dash lines in  FIG. 8B . As a result, the connection mechanism  10   d  impairs the air-directing function of the register  10 . Therefore, the connection mechanism  10   d  is demanded to have a structure which can improve the air-directing function. 
       SUMMARY OF THE INVENTION 
       [0019]    Accordingly, an object of the present invention is to provide a vehicle-cabin air outlet device which employs a connection mechanism which can meet at least one of the above-described demands for the conventional connection mechanism. 
         [0020]    The present invention is directed to an air outlet device for a vehicle cabin. The present invention is applicable to an air outlet device comprising a tubular body which forms an air guide passage; a plurality of front-side parallel wind-direction adjustment plates rotatably supported inside the tubular body at a front end thereof; a plurality of rear-side parallel wind-direction adjustment plates which are perpendicular to the front-side wind-direction adjustment plates and rotatably supported inside the tubular body at a position shifted rearward from the front end by a predetermined distance; and an operation knob which is assembled to a selected one of the front-side wind-direction adjustment plates to be slidable along a longitudinal direction thereof. The operation knob is operatively connected to a selected one of the rear-side wind-direction adjustment plates via a connection mechanism. The rear-side wind-direction adjustment plates are swung in a mutually interlocked manner when the operation knob is slid on the selected front-side wind-direction adjustment plate along the longitudinal direction. 
         [0021]    In the air outlet device according to the present invention, the connection mechanism comprises a connection pillar portion formed integrally with an intermediate portion of the selected rear-side wind-direction adjustment plate, the connection pillar portion having a generally circular cross section and being located “coaxially” to the selected rear-side wind-direction adjustment plate (i.e. located in such a manner that the connection pillar overlaps the main portion of the selected rear-side wind-direction adjustment plate in a plan view); and a pair of connection arm portions extending rearward from a rear end of the operation knob with a predetermined space formed therebetween. The operation knob is connected to the selected rear-side wind-direction adjustment plate in a state where the connection pillar portion is rotatably inserted into an engagement groove between the connection arm portions. 
         [0022]    In the air outlet device according to the present invention, the shape of the parting line PL between a stationary die half and a movable die half of a molding die can be simplified, and the stationary and movable die halves do not have a plurality of narrow projections, so that the strength of the molding die can be made higher than those of conventional molding dies. 
         [0023]    The connection mechanism is configured such that the operation knob is connected to the selected rear-side wind-direction adjustment plate in a state where the single connection pillar portion provided on the selected rear-side wind-direction adjustment plate is inserted into the engagement groove between the two connection arm portions provided on the operation knob. Therefore, the connection pillar portion is located within the engagement groove between the connection arm portions while the operation knob is being slid on the front-side wind-direction adjustment plate so as to swing the rear-side wind-direction adjustment plates. Therefore, the load acting on the operation knob does not change suddenly during the sliding operation of the operation knob, and a person who operates the operation knob does not feel a resistance during the operation, so that the operation feel is not impaired. 
         [0024]    The air outlet device according to the present invention may be configured as follows. The selected rear-side wind-direction adjustment plate is longitudinally divided into two adjustment plate portions. A pair of support plate portions are formed integrally with end portions of the adjustment plate portions such that the support plate portions face each other. A pair of connection plate portions are formed integrally with the support plate portions such that the connection plate portions extend between mutually facing side edge portions of the support plate portions so as to connect the support plate portions together. The connection pillar portion is formed integrally with the support plate portions, is located frontward of the connection plate portions. The connection pillar portion is also located around center of the support plate portions or between imaginary lines extending forward from the connection plate portions. These portions constitute a first connection mechanism portion. The operation knob is connected to the selected rear-side wind-direction adjustment plate in a state where the connection pillar portion of the first connection mechanism portion is rotatably inserted into the engagement groove between the connection arm portions, which constitute a second connection mechanism portion. 
         [0025]    When the connection mechanism having the above-described structure is used, the connection plate portions complement the wind-direction adjusting function of the wind-direction adjustment plate portions. Therefore, even when the rear-side wind-direction adjustment plate group is swung, a guide passage which causes air to flow straight is not formed, and the air-directing function of the air outlet device is not impaired. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    Various other objects, features and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description of the preferred embodiment when considered in connection with the accompanying drawings, in which: 
           [0027]      FIG. 1  is a front view of a register which is one embodiment of the vehicle-cabin air outlet device according to the present invention; 
           [0028]      FIG. 2  is a perspective view of the register of  FIG. 1 ; 
           [0029]      FIG. 3  is a vertically sectioned side view of the register of  FIG. 1 ; 
           [0030]      FIG. 4  is a horizontally sectioned plan view of the register of  FIG. 1 ; 
           [0031]      FIG. 5A  is a schematic view showing a state where the vertical blade group of the register of  FIG. 1  is molded within a molding die; 
           [0032]      FIG. 5B  is a schematic view showing the flow direction of air discharged from an air outlet opening portion when the vertical blade group is swung; 
           [0033]      FIG. 6  is a vertically sectioned side view of a register which is a conventional vehicle-cabin air outlet device; 
           [0034]      FIG. 7  is a horizontally sectioned plan view of the register of  FIG. 6 ; 
           [0035]      FIG. 8A  is a schematic view showing a state where the vertical blade group of the register of  FIG. 6  is molded within a molding die; and 
           [0036]      FIG. 8B  is a schematic view showing the flow direction of air discharged from an air outlet opening portion when the vertical blade group is swung. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0037]    The present invention relates to a vehicle-cabin air outlet device.  FIGS. 1 to 4  show a register  20  which is one embodiment of the air outlet device according to the present invention. The register  20  is connected to an end of an air duct of an air conditioner disposed at the back of an instrument panel provided on the front side of a vehicle cabin, and is assembled to the instrument panel. In a state where the register  20  is assembled to the instrument panel, an air outlet opening portion of the register  20  faces the interior of the vehicle cabin. 
         [0038]    The register  20  includes a retainer  20   a , which is a rectangular tubular body for forming an air guide passage; a horizontal blade group  20   b  composed of a plurality of horizontal blades (wind-direction adjustment plates) which are arranged in parallel in the vertical direction and rotatably supported inside the retainer  20   a  at a position near a front end opening thereof; a vertical blade group  20   c  composed of a plurality of vertical blades (wind-direction adjustment plates) which are arranged in parallel in the horizontal direction and are rotatably supported inside the retainer  20   a  at a position shifted rearward from the horizontal blade group  20   b  by a predetermined distance; and a connection mechanism  20   d  for operationally connecting an operation knob to the vertical blades. These constituent members are all resin molded products formed of a synthetic resin material. 
         [0039]    The vertical blades of the vertical blade group  20   c , a connection rod  23   e  (which will be described later) for connecting the vertical blades together, and a support plate  23   f  (which will be described later) for rotatably supporting the vertical blades are molded in a molding die  20   e  schematically shown in  FIG. 5A . The molding die  20   e  is configured to enable the vertical blades of the molded vertical blade group  20   c  to be assembled to the molded connection rod  23   e  and the molded support plate  23   f  within the molding die  20   e . Notably, in  FIG. 5A , reference numeral  20   e   1  denotes a stationary die half, reference numeral  20   e   2  denotes a movable die half, and reference character PL denotes a parting line at which the movable die half  20   e   2  can be separated from the stationary die half  20   e   1 . 
         [0040]    In the register  20 , an operation knob  22  is assembled to a selected horizontal blade  21  located at a central portion in the horizontal blade group  20   b . The operation knob  22  is assembled to the horizontal blade  21  to be slidable in the horizontal direction (the longitudinal direction). The connection mechanism  20   d  is formed between the operation knob  22  and a selected vertical blade  23  located at a central portion in the vertical blade group  20   c . The connection mechanism  20   d  is composed of a first connection mechanism portion  20   d   1  provided on the vertical blade  23  and a second connection mechanism portion  20   d   2  provided on the operation knob  22  side. 
         [0041]    As shown in  FIGS. 3 to 5 , the vertical blade  23  is divided into upper and lower blade portions  23   a   1  and  23   a   2 . Flat support plate portions  23   b   1  and  23   b   2  are integrally formed at mutually facing ends of the upper and lower blade portions  23   a   1  and  23   a   2 . The first connection mechanism portion  20   d   1  includes these support plate portions  23   b   1  and  23   b   2 ; a pair of connection plate portions  23   c   1  and  23   c   2  molded integrally with the support plate portions  23   b   1  and  23   b   2  to extend between the mutually facing side edge portions of the support plate portions  23   b   1  and  23   b   2  and connecting together the support plate portions  23   b   1  and  23   b   2 ; and a connection pillar portion  23   d  having a circular cross section, located at a position which is almost center in width direction (direction along the arrangement of the vertical blades) and is front-end side of the support plate portions  23   b   1  and  23   b   2  (frontward of the connection plate portions  23   c   1  and  23   c   2  ), formed integrally with the support plate portions  23   b   1  and  23   b   2  to connect the support plate portions  23   b   1  and  23   b   2  together. Such a structure of the first connection mechanism portion  20   d   1  enables the movable die half  20   e   2  to be separated from the stationary die half  20   e   1  at the parting line PL, serving as a reference line. The vertical blade group  20   c  provided with the first connection mechanism portion  20   d   1  is assembled to the connection rod  23   e  and the support plate  23   f  so as to form an assembly structure, which is assembled into the retainer  20   a.    
         [0042]    Meanwhile, the second connection mechanism portion  20   d   2  is formed integrally with a rear portion of the operation knob  22 , which is assembled to the horizontal blade  21  to be slidable in the horizontal direction. The second connection mechanism portion  20   d   2  includes left and right connection arm portions  22   a  and  22   b  provided at the rear portion of the operation knob  22 . The operation knob  22  is operationally connected to the vertical blade  23  in a state where the connection pillar portion  23   d  of the first connection mechanism portion  20   d   1  is inserted into an engagement groove  22   c  between the connection arm portions  22   a  and  22   b.    
         [0043]    The vertical blade group  20   c  including the vertical blade  23 , on which the first connection mechanism portion  20   d   1  of the connection mechanism  20   d  is provided, is molded between the stationary die half  20   e   1  and the movable die half  20   e   2  of the molding die  20   e , as shown in  FIG. 5A . After completion of molding, the movable die half  20   e   2  is separated from the stationary die half  20   e   1 , and the vertical blade group  20   c  is released from the die. Within the molding die  20   e , the released vertical blade group  20   c  is assembled to a predetermined portion within the retainer  20   a  by means of an unillustrated assembly jig provided in the molding die  20   e , whereby the vertical blade group  20   c  is rotatably supported in the retainer  20   a.    
         [0044]    In the register  20  having the connection mechanism  20   d  configured as described above, when the flow of air discharged from the air outlet opening portion is to be directed upward (downward) through a swing motion of the horizontal blade group  20   b  located on the front side, the operation knob  22 , which is assembled to the horizontal blade  21 , is turned or rotated upward (downward). As a result, the horizontal blade  21  swigs upward (downward), and simultaneously, all the horizontal blades (horizontal blade group  20   b ) connected to the horizontal blade  21  via a connection rod  21   a  swing in the same direction in an interlocked manner, whereby the air discharged from the air outlet opening portion is directed to a direction to which the horizontal blade group  20   b  is swung. 
         [0045]    When the flow of air discharged from the air outlet opening portion is to be directed leftward (rightward) through a swing motion of the vertical blade group  20   c  located on the rear side, the operation knob  22  is slid leftward (rightward) on the horizontal blade  21 . As a result, the vertical blade  23  swigs leftward (rightward), and simultaneously, all the vertical blades (vertical blade group  20   c ) connected to the vertical blade  23  via the connection rod  23   e  swing in the same direction in an interlocked manner, whereby the air discharged from the air outlet opening portion is directed toward a direction to which the vertical blade group  20   c  is swung. 
         [0046]    Incidentally, the above-described structure of the first connection mechanism portion  20   d   1  of the connection mechanism  20   d  provided in the register  20  enables the first connection mechanism portion  20   d   1  to be molded integrally with the vertical blade group  20   c  between the stationary die half  20   e   1  and the movable die half  20   e   2  of the molding die  20   e . Since the mutually facing portions of the stationary die half  20   e   1  and the movable die half  20   e   2  have simple shapes as indicated by the parting line PL of  FIG. 5A , a plurality of narrow projections are not present between the mold halves  20   e   1  and  20   e   2 . Therefore, the molding die  20   e  is higher in strength than the conventional molding die  10   e  shown in  FIG. 8A . 
         [0047]    In the case of the connection mechanism  20   d  provided in the register  20 , when the vertical blade group  20   c  is swung in an interlocked manner, the connection pillar portion  20   d  of the first connection mechanism portion  20   d   1  is always located within the engagement groove  22   c  between the connection arm portions  22   a  and  22   b  of the second connection mechanism portion  20   d   2 . Therefore, the load acting on the operation knob  22  does not change suddenly during the sliding operation of the operation knob  22 , and a person who operates the operation knob  22  does not feel a resistance during the sliding operation of the operation knob  22 , so that the operation feel is not impaired. 
         [0048]    Further, since the first connection mechanism portion  20   d   1  of the connection mechanism  20   d  provided in the register  20  has the above-described structure, the connection plate portions  23   c   1  and  23   c   2  provided between the support plate portions  23   b   1  and  23   b   2  to extend between the mutually facing side edge portions thereof have an air direction adjustment function similar to that provided by the blade portions  23   a   1  and  23   a   2  of the vertical blade  23 , as indicated by alternate long and short dash lines in  FIG. 5B . Therefore, in the case of the first connection mechanism portion  20   d   1 , even when the vertical blade group  20   c  is swung, a guide passage which causes air to flow straight is not formed, and the air-directing function of the register  20  is not impaired.