The present invention relates generally to an encapsulated fixed window module for a motor vehicle and such a motor vehicle.
In a number of motor vehicles, a door assembly is designed such that there is a first, e.g., forward, window opening that carries a movable window pane and a second, e.g., rearward, opening that is equipped with a fixed or stationary window pane. Of course, the forward window pane may be fixed and the rearward window pane may be moveable. Fixed windows of conventional design may be assembled from discrete elements that include the window panel, a post that serves as a track for an adjacent movable window and various configurations of moldings or trim pieces or division posts, most specifically an extruded header/B-pillar trim piece that may be mechanically attached to the window module assembly using an interlocking channel or the like.
The division post in some prior art designs comprises an article in the nature of a pre-formed resilient band. In those designs, the window is inserted into a channel of the trim band which resiliently engages the window pane, but often less than securely. Conventional designs suffer from a number of deficiencies due to their assembly from discrete components such as water leakage, noise from the exterior (wind noise) or the interior, and problems generally with fit and finish. In addition, the assembly of these modules is often difficult, particularly where the individual components are manufactured by more than one supplier.
A few of the problems of conventional designs are overcome through the use of over-molding processes by which a portion of the trim or post surrounding the window pane is fabricated by encapsulating the window periphery with a polymer using injection molding techniques. In essence, the window pane is placed in a mold cavity which is configured to produce a circumferential trim at the pane edges. A division post profile and a header profile are also placed in the mold cavity. In some cases, an additional margin seal extrusion can be added to the mold cavity. The edges of the pane on which the injection molded trim will adhere are cleaned and primed to promote adhesion and to create a water-impervious seal in the formed article. The mold is then closed and the material is injected such that the window pane edges are encapsulated to form the desired trim geometry.
The division post 3 is U-shaped in cross section and has an exterior wall 3a, an interior wall 3b, and a lateral wall 3c connecting said exterior and interior walls 3a, 3b. The division post 3 defines a longitudinal groove 5 configured to receive a portion of the movable window pane 2. The lateral wall 3c of the division post 3 is in abutment against the peripheral edge 1c of the fixed window pane 1 and said over-molded material 4 comprises a first portion 4a extending between the lateral wall 3c and the exterior surface 1a, and a second portion 4b extending between the lateral wall 3c and the interior surface 1b.
This configuration creates a small offset O between the interior surface 1b and the interior wall 3b and requires limited amount of over-molded material on both sides of the fixed window pane 1. The risk of appearance issue due to sink marks is therefore low.
The exterior appearance of the window modules is very important for the customer, i.e., the user of the motor vehicle. A solution for enhancing the appearance of a window module is to provide the periphery of the window pane with finished panels which are located outside the motor vehicle and are visible by the user. Said finished panels are for instance esthetic metal components which are secured to the window module.
It is also known to enhance the esthetic appearance of a window module by lying flush the outside of its stationary window pane with the outside of an adjacent movable window pane.
The division post 3 defines a longitudinal groove 5 configured to receive a guiding mean 6 carried by the movable window pane 2. The exterior wall 3a of the division post 3 faces the interior surface 1b and is secured thereto by the over-molded material 4.
The over-molded material 4 comprises a first portion 4a extending between the exterior wall 3a and the interior surface 1b and a second portion 4b extending between the lateral wall 3c and the interior surface 1b.
The over-molded material 4 comprises an outer face 4c which extends between the lateral wall 3c and the interior surface 1b and which includes a major portion 4c1 which is inclined with respect to the interior surface 1b. Due to feasibility reasons, it is not possible to get a major portion 4c1 perpendicular to the interior surface 1b during the over-molding process.
In this flush configuration, a large offset O is created between the interior surface 1b and the interior wall 3b and a large amount of over-molded material 4 is needed to fill this offset O. The risk of appearance issue due to sink marks is therefore high. Indeed, after de-molding, the over-molded material 4 cools and hardens. The large amount of over-molded material promotes the formation of sink marks and surface defects on the outer face 4c. Since this outer face 4c may be visible to the user of the motor vehicle, these sink marks and surface defects are problematic.
The present invention provides at least an encapsulated fixed window module which can be used in a flush configuration and which avoids at least some of the above-mentioned issues.
According to the invention there is provided an encapsulated fixed window module for a motor vehicle, comprising:
In the present specification, the words “inner”, “inside”, “interior”, etc., make reference to the inside of a motor vehicle. The words “outer” “outside”, “exterior”, etc., make reference to the outside of the motor vehicle. Then, an outer element is located at the outer side of the vehicle. A first outer element, portion or surface may be visible by a user of the motor vehicle or may be hidden by a second outer element, portion or surface covering said first outer element.
In the present specification, “aligned” and “substantially aligned” mean that two elements are strictly aligned or are aligned in a range 0 to 5 mm, preferably 0 to 3 mm and more preferably 0 to 1 mm.
The present invention provides a solution for enhancing the esthetic appearance of a fixed window module. This aim is achieved by keeping the thickness of the over-molded material as constant as possible. The second portion of the over-molded material is constant along a major portion of this second portion along a direction perpendicular to the interior surface of the fixed window pane. The thicknesses of the first and second portions of the over-molded material may be similar. Having a consistent thickness allows all the molded areas to cool at the same speed and prevent “sink-marks” and other appearance defects.
The encapsulated fixed window module according to the invention may comprise one or more of the following features, taken alone from each other or in combination with each other:
The invention further proposes a glass run comprising an encapsulated fixed window module as recited above and first and second extruded segments,
The glass run may comprise further profiles, and in particular third and fourth profiles, as described above. The invention further proposes a motor vehicle, comprising at least one encapsulated fixed window module or one glass run as defined above.
The motor vehicle may comprise a door including a door frame, a movable window pane, and said encapsulated fixed window module, said movable window pane having an exterior surface, an interior surface, and a peripheral edge extending between said exterior and interior surfaces, wherein said exterior surfaces of said encapsulated fixed window module and of said movable window pane are substantially coplanar or flush.
Advantageously, both exterior surfaces of said encapsulated fixed window module and of said movable window pane are further substantially coplanar or flush with a portion of a first sealing lip interposed between both peripheral edge of said encapsulated fixed window module and of said movable window pane.
The invention will be better understood and other details, features and advantages of the invention will appear more clearly on reading the following description given by way of non-limiting examples and with reference to the accompanying drawings in which:
A motor vehicle door comprises a door frame provided with an encapsulated fixed window module 10 which can be adjacent to a movable window pane 12. In the example of
The module 10 includes at least a fixed window pane 14 molded on up to four extremities or along four edges. The or each molding forms an encapsulation 16.
Each pane 12, 14 has an exterior surface 12a, 14a intended to be located outside the motor vehicle, an interior surface 12b, 14b intended to be located inside the motor vehicle, and a peripheral edge 12c, 14c extending between said exterior and interior surfaces (see
Each pane 12, 14 may be substantially flat. Thus, its surfaces 12a, 14a, 12b, 14b may be substantially flat. Of course, the pane 12, 14 and its surfaces may be slightly curved according to the expected design of the module. As shown in
In the example shown, each pane 12, 14 has a polygonal shape and comprises four longitudinal edges. Each peripheral edge 12c, 14c includes therefore a top edge 12ca, 14ca, a front edge 12cb, 14cb, a bottom edge 12cc, 14cc and a rear edge 12cd, 14cd (see
These figures show that the encapsulation 16 extends along the edges 14ca, 14cb and 14cd of the pane 14. Glass edge 14ca and the inboard side of the glass next to 14cb are encapsulated. Encapsulation of glass edges 14cd and 14cc is optional.
Thus, the encapsulation 16 extends along at least two edges of the pane 14 in the example shown but may not necessarily cover these edges as will be detailed below. The encapsulation 16 may comprise segments or profiles or division posts each extending along a portion of the longitudinal edges of the pane 14. Each profile of the division post has a length and a width, its length being greater than its width and extending along said portion of the longitudinal edges of the pane 14.
A substantially vertical profile (not shown) is molded to profile 18 to be part of module 10, in order to guide the moveable glass edge 12cb.
The third profile 18 shown in
The first U-shaped portion 18a defines a longitudinal groove 24 that is oriented inwardly and is configured to receive a metallic flange 26 of the motor vehicle. In the example shown, the metallic flange includes two substantially horizontal panels that are superimposed and inserted into the groove 26. The first portion 18a includes an exterior wall 18aa connecting two lateral walls 18ab, 18ac defining the groove 26 therebetween.
The second U-shaped portion 18b defines a longitudinal groove 28 that is oriented downwardly in a plane parallel to the panes 12, 14 and which is configured to receive by sliding an upper portion of the movable window pane 12. The second portion 18b includes an interior wall 18ba and an exterior wall 18bb connected by a lateral wall which may be integrated in said lateral wall 18ac as shown in the figure. The walls of the second portion 18b define said groove 28.
Both portions 18a, 18b include sealing lips intended to cooperate with the pane 12 and/or parts of the vehicle.
The third profile 18 further may include an elongated esthetic component 30 which extends along the profile 18 and is secured onto both portions 18a, 18b. The component 30 includes an esthetic exterior face 30a and an interior face 30b. The component 30 includes a substantially flat portion including the faces 30a, 30b and longitudinal hooks 30c extending inwardly from the inner face 30b. The hooks 30c are used to mechanically secure the component 30 onto the profile 18. The component 30 is intended to cover at least portions of said exterior walls 18aa, 18bb which both comprise grooves intended to receive the hooks 30c by snap fitting.
This portion of the profile 18 differs from the portion of
This over-molded material 50 extends onto the inner surface of the exterior wall 18bb, the downward surface of the lateral wall 18ac and also over the edge 14ca and portions of the surfaces 14a, 14b of the fixed window pane 14. This over-molded material 50 may have lips or legs intended to abut against parts of the vehicle.
The second profile 20 shown in
The second profile 20 includes an exterior wall 20a and two lateral walls 20b, 20c connected by said exterior wall 20a. The exterior wall 20a is usually parallel to the interior surface 14b of the fixed window pane 14 and is secured thereto by an over-molded material 36. In the example shown, the exterior wall 20a faces the interior surface 14b and spaced therefrom. This space S is filled in with said over-molded material 36.
The lateral wall 20b is substantially aligned with a portion (the rear edge 14cd in the example shown) of said peripheral edge 14c in a plane P1 that is perpendicular to the fixed window pane 14. The lateral wall 20c extends perpendicularly to and faces the interior surface 14b.
In the example shown, the over-molded material 36 further extends over the lateral wall 20c and the frond edge 14cd. The lateral wall 20b is free of such over-molded material 36. Said over-molded material 36 is V-shaped (with an angle lower than) 90° in front of the rear edge 14cd and defines a first planar surface 36a aligned with the exterior surface 14a and a second planar surface 36b which extends between the first surface 36a and the profile 20 and is inclined with respect to said plane P1.
The second profile 20 includes sealing or retention lips intended to cooperate with parts of the vehicle.
The first profile 22 shown in
The first profile 22 includes an exterior wall 22a and an interior wall 22b connected together by a lateral wall 22c and defining the groove therebetween. The exterior wall 22a is parallel to the interior surface 14b of the fixed window pane 14 and is secured thereto by an over-molded material 42. In the example shown, the exterior wall 22a faces the interior surface 14b and is L-shaped in cross section. The exterior wall 22a includes first and second parts 22aa, 22ab that are perpendicular to one another, said first part 22aa being spaced from the interior surface 14b and extending between said lateral wall 22c and said second part 22ab. Said second part 22ab is applied directly onto said interior surface 14b. Said first part 22ab defines a space S with said interior surface 14b that is filled in with the over-molded material 42.
The over-molded material 42 further extends over at least a portion of said lateral wall 22c. The over-molded material 42 does not cover the peripheral edge 14cb along said first profile 22, i.e., the front edge 14cb, in the example shown.
The exterior wall 22a has a longitudinal edge 22a1 which is opposite to the lateral wall 22c that is substantially aligned with said front edge 14cb in a plane P2 that is perpendicular to the fixed window pane 14.
This longitudinal edge 22a1 carries a first sealing lip 44 which is configured to abut against both edges 14cb and 12cd. The sealing lip 44 is the sole member extending between said edges 14cb and 12cd. The sealing lip 44 is curved (concave or convex) and defines a groove oriented inwardly. The lip 44 includes a longitudinal connecting edge 44a which extends in the plane P2 and is secured to the longitudinal edge 22a1, and further includes an opposite longitudinal sealing edge 44b abutting against the rear edge 12cd of the pane 12. The longitudinal portion of the sealing lip 44 extending between both edges 44a, 44b has an exterior surface 44c which is substantially aligned with said exterior surfaces 14a, 12a.
As far as the interior wall 22b of the first profile 22 is concerned, it crosses said plane P2 and is configured to face said guiding mean 40, and preferably also to face the interior surface 12b of the movable window pane 12 as shown in the figure.
The interior wall 22b carries a second sealing lip 46 which is configured to be in sealing contact with the guiding mean 40. In another example, only the first and the third sealing lips may be provided (no sealing is then provided on the guiding mean 40).
The guiding mean 40 may be formed of a single longitudinal part that is secured, for instance by gluing or over-molding, onto the interior surface 12b of the pane 12 and includes a guiding leg 40a crossing the plane P2 and received into the groove 38 for sliding motion. As shown in the drawings, the surfaces of the groove 38 may be coated with an antifriction layer suitable to cooperate by sliding with the guiding mean 40 and in particular its leg 40a. Therefore, as shown in the drawings, the walls 22a, 22b, 22c may be coated with the antifriction layer inside the groove 38.
As shown in
The reference numerals used in relation to
The window panes 12 and 14 are similar to the ones disclosed above. The guiding mean 40 is also similar.
The (first) profile 122 or division post of
The profile 122 shown in
The profile 122 includes an exterior wall 22a and an interior wall 22b connected together by a lateral wall 22c and defining the groove 38 therebetween. The exterior wall 22a is parallel to the interior surface 14b of the fixed window pane 14 and is secured thereto by an over-molded material 142.
As shown in the drawings, the surfaces of the groove 38 may be coated with an antifriction layer F1 suitable to cooperate by sliding with the guiding mean 40 and in particular its leg 40a. Therefore, as shown in the drawings, the walls 22a, 22b, 22c may be coated with the antifriction layer F1 inside the groove 38.
The exterior wall 22a has a surface 22a1 that faces the interior surface 14b and is L-shaped in cross section. The exterior wall 22a includes first and second parts 22aa, 22ab that are perpendicular one another, said first part 22aa being spaced from the interior surface 14b and extending between said lateral wall 22c and said second part 22ab. Said second part 22ab is applied directly onto said interior surface 14b in the vicinity of the edge 14c, 14cb.
Said second part 22ab carries a protruding leg 160 which extends externally in a direction substantially perpendicular to the exterior wall 22a. The protruding leg 160 is interposed in the gap between both peripheral edges 12cb, 14cb, and is in abutment against the peripheral edge 14cb. The protruding leg 160 carries a first sealing lip 44 which is configured to abut against the edge 12cb. The first sealing lip 44 has an exterior surface 44c which is substantially aligned with the exterior surfaces 14a, 12a.
The protruding leg 160 is made of the same material as the main material (or polymeric covering) of the profile 122. The first sealing lip 44 is preferably made of a softer material.
The exterior wall 22a, and in particular its first part 22aa, defines a space S with the interior surface 14b that is filled in with the over-molded material 142 and in particular with a first portion 142a of this over-molded material 142.
The over-molded material 142 further extends over at least a portion of said lateral wall 22c and comprises a second portion 142b extending between the lateral wall 22c and the interior surface 14b. The over-molded material 142 does not cover the peripheral edge 14cb in the example shown.
As far as the interior wall 22b of the first profile 22 is concerned, it is longer than the exterior wall 22a and is configured to face said guiding mean 40, and preferably also to face the interior surface 12b of the movable window pane 12 as shown in the figure.
The interior wall 22b carries a second sealing lip 46 which is configured to be in sealing contact with the guiding mean 40, and a third sealing lip 48 which is configured to be in sealing contact with the interior surface 12b of the movable window pane 12.
Sealing lips 44, 46 and 48 may be coated with antifriction layers F1.
In another example, only the first and the third sealing lips may be provided (no sealing is then provided on the guiding mean 40).
The profile 122 may comprise at least one U-shaped metallic rail embedded or encapsulated into a polymeric covering. This rail may include a first branch extending into the exterior wall 22b, a second branch extending into the interior wall 22a, and a connecting branch extending into the lateral wall 22c.
The profile 122 and its polymeric covering may be made by co-extrusion. The sealing lips may be made of an elastically deformable material, such as for example EPDM or thermoplastic. These lips may be realized by over-molding or co-extrusion. Of course, the profile 122 might not comprise metallic rail and might therefore comprise only a polymeric material. The polymeric or covering material of the profile 122 may be a thermoplastic or an elastomer thermoplastic, such as for instance polypropylene. The over-molded material is for instance made of thermoplastic, elastomer thermoplastic, EPDM, SEBS, etc.
As shown in
The second portion 142b of the over-molded material 142 has a second thickness E2 which is constant along a major portion of the second portion. The thickness E2 of this second portion 142b is measured in a direction which is perpendicular to the lateral wall 22c.
This second portion 142b has an outer face 142b1 which extends between the lateral wall 22c and the interior surface 14b and which includes a major portion which is inclined with respect to the interior surface 14b.
In the shown example, the over-molded material 142 is V-shaped and includes both portions 142a, 142b connected therebetween and forming together a tip 142c. The over-molded material 142 includes a protruding rib 166 on its tip 142c, this protruding rib 166 extending on the interior surface 14b (
In the example shown, the shape of the over-molded material is provided by the shape of the profile 122 which includes a tooth 168 or a fin (such as a shark fin) on its lateral wall 22c.
The tooth 168 includes a first surface 168a parallel to the interior surface 14b and aligned with the surface 22a1 of the exterior wall 22a, and a second surface 168b which is inclined with respect to the interior surface 14b. The function of tooth 168 is to create a constant offset between the second surface 168b and the outer face 142b1. The shape and location of the surface 168b will thus evolve according to the shape and location of the outer face 142b1. The thickness E2 of the second portion 142b may be measured in a direction which is perpendicular to this second surface 168b.
The tooth 168 is preferably fully embedded into the over-molded material so that the first portion 142a extends between the first surface 168a and the interior surface 14b and the second portion 142b extends between the second surface 168b and the interior surface 14b. The first surface 168a is planar and the second surface 168b is also planar in the example shown. This second surface 168b is preferably parallel to the outer face 142b1 to ensure that E2 is constant. The first and second surfaces 168a, 168b are therefore V-shaped in cross section in the example shown. The first and second surfaces 168a, 168b form an angle □ or form a tip having an angle which is comprised between 2° and 85°, and preferably between 5° and 70°. In other words, the tooth 168 defines an angle □ comprised between 2° and 85°, and preferably between 5° and 70°.
The invention relates to an encapsulated fixed window module which is similar to the encapsulated window module described above in relation with
According to the invention, the over-molded material 142 is in contact with at least one protruding lip 162 (only described later on
The embodiment of
In the enlarged detailed view of
The exterior wall 22a is located at a first distance D3 from the interior surface 14b, said first distance being measured in a direction which is perpendicular to said interior surface 14b. The protruding lip 162 has a first height H1 in said first position and a second height H2 in second position, said first and second heights being measured in a direction which is perpendicular to said interior surface. The second height H2 is equal to the first distance D3, and the first height H1 is greater than the second height H2 and the first distance D3.
The protruding lip 162 and the protruding leg 160 may be made of the same material as the main material of the profile 122. The first sealing lip 44 is made of a softer material.
The over-molded material 142 does not cover the peripheral edge 14cb. This is due to the presence of the protruding lip 162 which abuts against the pane 14 and avoid over-molded material 142 passing through the lip 162 and up to the edge 14cb.
As shown in the drawings, the protruding lip 162 and leg 160 may define together and with the pane 14 a space S′ that is empty, i.e., that is not filled with over-molded material 142.
The embodiment of
The embodiment of
The embodiment of
The embodiment of
The embodiment of
The embodiment of
The third portion 142c extends on the peripheral edge 14cb of the fixed pane 14. The third portion 142c is perpendicular to the first portion 142a and extends outwardly from the end of the first portion 142a which is opposite to the second portion 142b. The third portion 142c covers entirely the peripheral edge 14cb in the example shown.
Therefore, the profile 122 is not directly in contact with the pane 14. Its exterior wall 22b is remote from the interior surface 14b and is separated therefrom by the over-molded material 142.
The first sealing lip 44 of the profile 122 is configured to abut against edge 12cd. The third portion 142c and the sealing lip 44 are both located between the edges 14cb and 12cd.
As shown, the third portion 142c may include an end which is coplanar with said exterior surfaces of said panes 12, 14.
The embodiment of
The embodiment of
In another embodiment shown in
In another embodiment of the invention shown in
The protruding leg 160 and the protruding lip 162 may also be made of a material which is different from the main material of the profile 122. The materials of the leg 160, of the lip 162 and of the tooth 168 may be the same.
Even if the tooth 168 and/or the protruding leg 160 and/or the protruding lip 162 may be made of different material, they are preferably made by co-extrusion with the profile 122. Use of a softer material for the protruding leg 160 for instance enhances the molding operation.
The second portion 142b extends on the tooth 168 and has an end linked to the profile 122. This portion 142b has a constant thickness E2 up to this end.
In the embodiment of
The embodiment of
There are three protruding lips 162 between the exterior wall 22a and the interior surface 14b in the embodiment of
In all the figures showing the invention, the protruding lip(s) may be considered as comprising a securing base 162a and at least one flexible lip 162b extending from said securing base 162a.
In the embodiments of
The securing base 162a is secured to the division post 22 and in particular to its exterior wall 22b (an more specifically the exterior face of the exterior wall facing the interior face 14b). The flexible lip(s) 162b extends outwardly from the securing base 162a. The flexible lips 162b are adjacent one another. The space between two adjacent lips 162b may be empty or filled with over-molded material. The flexible lips 162b may be identical or different from one another. Each of said adjacent protruding lips are elastically-deformable;
In the embodiments of
In the embodiments of
In the former embodiments showing the invention, the protruding lip 16 is located at a first end of the exterior wall 22a which is opposite to the lateral wall 22c. To the contrary, in the embodiment of
In this embodiment of
The distance D3 between the exterior wall 22a and the interior surface 14b is here null. Height H1 is greater than H2 which is close to zero in this embodiment.
In the former embodiments showing the invention, the protruding lip 16 is carried by said exterior wall 22a.
In the embodiments of
As described above, the protruding lip(s) 162 may be considered as comprising a securing base 162a and at least one flexible lip 162b extending from said securing base 162a.
In the embodiments of
The securing base 162a is secured to the interior surface 14b and the flexible lip(s) 162b extend inwardly from the securing base 162a. The flexible lips 162b are adjacent one another. The space between two adjacent lips 162b may be empty or filled with over-molded material. The flexible lips 162b may be identical or different from one another. Each of said adjacent protruding lips are elastically-deformable.
The protruding lips 162 of
As shown, the convex side 162d may be aligned and flush with a convex surface of said peripheral edge 14cb. In variant, said convex side is remote from said convex surface of said peripheral edge.
In the embodiments of
In the embodiments of
In all these embodiments, the protruding leg 160 carries a sealing lip 44 which is configured to abut against the peripheral edge 12c of the movable window pane 12. This first sealing lip 44 has a concave surface 44d which is oriented outwardly and opposite to the division post 22.
The embodiment of
The embodiment of
The first extruded segment 202 is parallel to the division post 22. The second extruded segment 204 extends between the encapsulated fixed window module 10 and the first extruded segment 202 and has a first end 204a connected by overmolding to an upper end of the division post 202 and a second end connected by overmolding to an upper end of said first extruded segment 202. The second extruded segment 204 is similar to the third profile 18 as described above.
In all the embodiments, the esthetic appearance of the window module may be enhanced by lying flush the outside surfaces 12a, 14a of the fixed and movable window panes 12, 14. The exterior surfaces 12a, 14a of the panes 12, 14 may be therefore substantially coplanar. These surfaces 12a, 14a mays also be flush with the exterior surface 44c (cf.