Simple mirror sail seal for fixed sail construction
A one-piece composite mirror sail is disclosed for an associated vehicle that eliminates use of metal brackets. The sail includes a glass run that extends from beneath a belt line of a vehicle door window opening and extends above the associated belt line. A first portion of the glass run is an extruded EPDM first portion that extends from beneath the associated belt line. A second portion of the glass run is located above the belt line and is molded thermoplastic only. The first and second portions of the glass run are integrally joined, preferably along a fusion bonding interface. A coating is preferably provided on a base and seal lips of the extruded portion. An angled leg extends from the glass run second portion. The angled leg includes a retaining portion. The angled leg and retaining portion are molded thermoplastic only.
This application claims priority from U.S. provisional application Ser. No. 60/627,532, fled Nov. 12, 2004, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTIONThe present invention relates to a corner piece for an automobile, and more particularly to a mirror sail seal, that uses different materials at different portions of the mirror sail seal, i.e., specific part geometry, to improve on performance, cost, and ease of assembly.
U.S. Pat. No. 5,746,471 is one representative example of a corner piece such as a mirror sail seal used in an automotive vehicle. The '471 patent generally teaches an EPDM channel received in a metal bracket. It is common to extrude a channel-shaped EPDM over a U-shaped metal bracket and attach the EPDM in a suitable manner to the bracket.
An alternative structural arrangement for a mirror sail seal manufactures the component as a molded component, such as EPDM. Unfortunately, the shape of the sail seal is constrained by molding, thus, a molded EPDM mirror sail seal is not as desirable because of extended cycle times, and the need for the component to vulcanize.
There are competing functions of the sail seal. It will be appreciated that a portion of the component must be sufficiently rigid so as to eliminate the need for metal reinforcement or use of metal to secure the component to the vehicle. On the other hand, one portion of the mirror sail seal must be sufficiently conforming or soft as to form an effective, reliable seal with a moveable door glass. Still other portions of the sail seal must be more durable and resistant to glass abrasion, i.e., requiring a low-friction or slippery surface that is abrasion-resistant.
Heretofore, it is believed that no corner piece or mirror sail has been part geometry-specific, i.e., providing different materials at different locations or portions of the mirror sail seal while maintaining a one-piece arrangement for assembly purposes that serve these various functions. For example, large molds are required for an entirely molded mirror sail. Even then, multiple post-molding operations are still required such as adding flock along the glass run portions thereof. These post-molding steps increase the overall cost. In addition, such conventional materials such as flock and flock adhesive are deemed generally unfriendly to the environment.
Thus, a need exists for ease in manufacturing of a simple mirror sail seal that is environmentally friendly and uses materials that are recyclable while providing a final component that improves sealing performance at the same or slightly better cost.
SUMMARY OF THE INVENTIONA composite mirror sail for an associated vehicle includes a glass run extending from beneath an associated belt line of a vehicle door window opening and extending above the associated belt line. The glass run has an extruded first portion that extends from beneath the associated belt line to a location above the associated belt line, and a second portion that is molded thermoplastic only. An angled leg extends from the glass run second portion and is formed from molded thermoplastic only.
BRIEF DESCRIPTION OF THE DRAWINGS
Turning briefly to
In order to provide a low-friction surface, those regions of the glass run portion 12 adapted to engage the inner and outer surfaces of the window, and likewise the edge of the glass, such as shown in the cross-section of
A preferred embodiment of the present invention as illustrated in
This cross-section of
Still another advantage is that the lips provide a constraining force or stabilizing force to the window, particularly below the belt line that removes undesired movement of the window that could otherwise result in noise or rattling.
Moreover, whereas the EPDM of
However, another embodiment merely coats the entire interior surface of the extruded glass run portion with the abrasion resistant plastic. This includes the second pair of lips 44, 46 that also engage the inner and outer surfaces of the window. Thus, the main channel of the extrusion is preferably an EPDM and the plastic is co-extruded therewith in a manner generally known in the art over the entire interior of the glass run channel such as the base, interior of the sidewalls, over the entire first set of lips, and at least along the inner surface of the second set of lips 44, 46.
This glass run channel portion extends from below the belt line BL to a region as high as possible within geometry and structural limitations—located well above the belt line, i.e., up to the interface 30. The extruded component with the abrasion resistant plastic is integrally joined with a thermoplastic elastomer (TPE) such as through a fusion bonding interface. Preferably, the remainder of the seal sail such as the second angled portion 60 and the generally rectangular attachment region 62 (including the integrated push pin(s) 64) is formed of the TPE, and is preferably molded. This has the advantage that the TPE plastic is durable, and is easier to work with than a conventionally molded EPDM. TPE is more rigid, and also has a faster cycling time. It also advantageously does not have to be vulcanized. Accordingly, some cost savings may be associated therewith. Generally, this TPE portion has the same conformation as a conventional sail seal. Thus, the cross-sectional view of
The present invention uniquely uses an extruded cross-section that incorporates an abrasion-resistant, slippery surface material along selected regions to provide desirable glass run properties below the belt. In that portion of the sail seal above the belt line, the molded TPE is sufficient to serve as the remainder of the glass run length while providing improved sealing performance at a lower cost. Moreover, the exterior show surface of the molded TPE is improved since it provides a textured surface having improved aesthetics over a conventional molded EPDM. The combination of a molded/extruded mirror sail in which the extrusion trim is secured to a TPE mold is deemed to be an improvement over prior arrangements. Bonding interface of the extruded component with the TPE mold also provides a generally seamless transition that does not adversely impact on manufacture. Simultaneously, use of the TPE for the mold material has the advantage that the textured surface provides improved aesthetics in those external regions formed of the TPE for this vehicle component. The ability to maintain an integrated fastener feature is still achieved, and it also adequately bonds to the extruded EPDM component. Lastly, the abrasion-resistant plastic is easily formed on the extruded component, preferably through a co-extrusion process. By providing an extended length of glass run with flexible sealing lips that extend inwardly toward the channel cavity, improved sealing is achieved and greater stability of the window during door operation.
The invention has been described relative to the preferred embodiments. Obviously modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention should be construed as including all such modifications and alterations in so far as they fall within the scope of the following claims.
Claims
1. A composite mirror sail for an associated vehicle, the sail comprising:
- a glass run extending from beneath an associated belt line of a vehicle door window opening and extending above the associated belt line, the glass run having an extruded first portion that extends from beneath the associated belt line to a location above the associated belt line, and a second portion that is molded thermoplastic only; and
- an angled leg extending from the glass run second portion that is molded thermoplastic only.
2. The invention of claim 1 wherein the first and second portions of the glass run are integrally joined to one another.
3. The invention of claim 2 wherein the first and second portions are fusion bonded together.
4. The invention of claim 1 further comprising an attachment portion extending from the angled leg at an end of the leg opposite from the glass run, the attachment portion also formed of a molded thermoplastic.
5. The invention of claim 1 wherein the first portion of the glass run includes selected portions of abrasion resistant plastic.
6. The invention of claim 5 wherein the glass run has a base and first and second sidewalls extending outwardly therefrom to form a channel-shape in cross section including a cavity dimensioned to receive an edge of the associated door window, the base of the channel and portions of the sidewalls including an abrasion resistant plastic.
7. The invention of claim 6 wherein the sidewall portions include a first set of seal lips that extend inwardly into the cavity for engagement with the associated window.
8. The invention of claim 6 wherein the sidewalls include first and second sets of seal lips dimensioned to engage the associated window.
9. The invention of claim 1 wherein the glass run has a base and first and second sidewalls extending outwardly therefrom to form a channel-shape in cross section including a cavity dimensioned to receive an edge of the associated door window, an entire internal surface of the glass run being coated in an abrasion resistant plastic.
10. A one-piece composite mirror sail for an associated vehicle that eliminates use of metal brackets, the sail comprising:
- a glass run extending from beneath an associated belt line of a vehicle door window opening and extending above the associated belt line, the glass run having an extruded EPDM first portion that extends from beneath the associated belt line to a location above the associated belt line, and a second portion above the associated belt line that is molded thermoplastic only, the first and second portions integrally joined along a fusion bonding interface; and
- an angled leg extending from the glass run second portion that is molded thermoplastic only.
11. The invention of claim 10 wherein the first and second portions of the glass run are integrally joined.
12. The invention of claim 10 wherein the first and second portions of the glass run are fusion bonded.
13. The invention of claim 10 wherein the first portion of the glass run includes a base and sidewalls extending therefrom, selected portions of which are coated with an abrasion resistant plastic.
14. The invention of claim 10 wherein the first portion of the glass run includes a base and sidewalls extending therefrom to define a cavity that receives an edge of an associated door glass, portions of the base and sidewalls facing the cavity including an abrasion resistant plastic coextruded thereon.
15. The invention of claim 14 wherein the sidewalls include a first set of seal lips extending inwardly into the cavity.
16. The invention of claim 15 further comprising a second set of seal lips extending inwardly into the cavity.
Type: Application
Filed: Nov 14, 2005
Publication Date: Jun 8, 2006
Inventors: Richard Hooker (Redford, MI), Chad Klopfenstein (Goshen, IN), Tom Glowacki (Westland, MI)
Application Number: 11/273,515
International Classification: A47G 1/00 (20060101);