The invention relates generally to seal assemblies adapted to be coupled to a flange of a vehicle.
Motor vehicles are typically equipped with vehicle doors and vehicle windows. The vehicle windows may be moveable (such as a vertical moving window of the vehicle door) or may be stationary (such as a quarter window on the vehicle door). The vehicle doors and vehicle windows are required to be sealed with a seal assembly. Seal assemblies commonly include a seal body comprised of an elastomeric material and a molded component comprised of a plastic material. Combining seal bodies comprised of elastomeric material and molded components comprised of plastic material in a single seal assembly is challenging due to the difficulty of bonding elastomeric material and plastic material without the aid of mechanical fastening which can add cost and manufacturing time to the seal assembly. Moreover, mechanical fastening often fails to provide a water-tight seal between the seal body and the molded component.
As such, there remains a need to provide an improved seal assembly.
A seal assembly is adapted to be coupled to a flange of a vehicle. The seal assembly includes a seal body extruded from an elastomeric material. The seal body has a base, a first leg extending from the base, and a second leg extending from the base spaced from the first leg. The base, the first leg, and the second leg collectively define a mounting channel for receiving the flange of the vehicle. The seal assembly also includes at least one seal feature co-extruded with the seal body. The seal feature extends from the seal body and is spaced from the mounting channel. The seal assembly further includes a molded component coupled to the seal body and molded from a thermoplastic material. The seal assembly further still includes an electromagnetic adhesive disposed between the seal body and the molded component. The electromagnetic adhesive is comprised of a resin and a susceptor configured to be energized upon exposure to electromagnetic energy such that the susceptor softens the resin to directly mount the molded component to the seal body.
A seal assembly adapted to be coupled to a flange of a vehicle, the seal assembly comprising a seal body extruded from an elastomeric material and having a base defining a mounting surface. At least one seal feature co-extruded with the seal body with the seal feature extending from the seal body and spaced from the mounting surface. A molded component coupled to the seal body and molded from a thermoplastic material with the molded component having an attachment feature for engaging the flange of the vehicle. An electromagnetic adhesive disposed between the mounting surface of the seal body and the molded component, with the electromagnetic adhesive comprised of a resin and a susceptor configured to be energized upon exposure to electromagnetic energy such that the susceptor softens the resin to directly mount the molded component to the seal body.
As such, the seal body extruded from the elastomeric material and the molded component molded from the thermoplastic material are directly mounted to one another through the electromagnetic adhesive. Direct mounting of the seal body and the molded component can thus be accomplished inexpensively and with reduced manufacturing time.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
With reference to the Figures, wherein like numerals indicate like parts throughout the several views, a seal assembly 10 is adapted to be coupled to a flange 11 of a vehicle. In one embodiment, as shown in
The seal assembly 10 further includes a molded component 24 coupled to the seal body 12 and molded from a thermoplastic material. The seal assembly 10 further still includes an electromagnetic adhesive 26 disposed between the seal body 12 and the molded component 24. The electromagnetic adhesive 26 is comprised of a resin 28 and a susceptor 30 configured to be energized upon exposure to electromagnetic energy such that the susceptor 30 softens the resin 28 to directly mount the molded component 24 to the seal body 12.
As such, the seal body 12 extruded from the elastomeric material and the molded component 24 molded from the thermoplastic material are directly mounted to one another through the electromagnetic adhesive 26. In a preferred embodiment, without a need for mechanical fastening as discussed below. Direct mounting of the seal body 12 and the molded component 24 can thus be accomplished inexpensively and with reduced manufacturing time. Moreover, the electromagnetic adhesive 26 results in a strong bond between the seal body 12 and the molded component 24, and thus the direct mounting of the seal body 12 to the molded component 24 is secure.
With reference to
It is to be appreciated that the flange 11 may be a component of the vehicle door or other vehicle panel. More specifically, the vehicle door may include a frame, such as a window frame, and the flange 11 may either be a component of the frame or may be a separate component from the frame which generally follows the contour of the vehicle door. Alternatively still, the vehicle may include a vehicle panel separate from the vehicle door, and the vehicle panel may include the flange 11. The vehicle panel may be a side panel, a front panel, or a roof panel, among other possibilities.
In another embodiment, as shown in
It is to be appreciated that the embodiment shown in
Moreover, still with reference to
As shown in
Additionally, the seal feature 22 may be further defined as a sealing lip 38 extending outwardly from the seal body 12. The sealing lip 38 may be flocked as described herein. Alternatively, the seal feature 22 may be a sealing bulb. The sealing bulb may also be flocked as described herein.
As shown in
The outer surface 40 may define a notch 42, and the electromagnetic adhesive 26 may be disposed in the notch 42, as shown in
As shown in
The electromagnetic energy may be further defined as an alternating magnetic field. The electromagnetic energy, whether taking the form of an alternating magnetic field or otherwise, may be applied to the electromagnetic adhesive 26 through use of a radiofrequency (RF) coil 44, as shown in
The radiofrequency (RF) coil 44 may be cooled, for example, by a coolant such as water. The radiofrequency (RF) coil emits the electromagnetic energy (e.g., creates an alternating magnetic field), which energizes the susceptor 30 in the resin 28. The susceptor 30 in the resin 28 may then increase in temperature, and heat is transferred to from the susceptor 30 to the resin 28. The resin 28 then softens in response to the heat transferred from the susceptor 30. The softened resin 28 bonds the seal body 12 to the molded component 24. The process of energizing the susceptor 30 and softening the resin 28 to mount the seal body 12 to the molded component 24 may be referred to as electromagnetic welding.
It is to be appreciated that the resin 28 need only soften and need not melt, although it is contemplated that the resin 28 may melt. The resin 28 may approach, but not reach, a melting point of the resin 28. However, it is further to be appreciated that the resin 28 may not even be capable of melting. In other words, the resin 28 may be comprised of a material without a melting point. Instead, as a non-limiting example, the resin 28 may be comprised of a material with a glass transition temperature. In these embodiments, the resin 28 may approach, or reach, the glass transition temperature of the resin 28.
The susceptor 30 may be further defined as a plurality of susceptor particles 46 impregnated in the resin 28. The susceptor 30 may also be a singular component, such as a strip, or may be divided into multiple components. The susceptor 30 may comprise a ferromagnetic material, whether in the form of the singular component, multiple components, or as the plurality of particles 46. The ferromagnetic material may include at least one chosen from iron, nickel, and magnetite. In other words, the susceptor 30 may include iron, nickel, magnetite, or any combination of iron, nickel, and magnetite.
The seal body 12 extends along an axis A1. In a non-limiting example, the electromagnetic adhesive 26 may be applied to the seal body 12 continuously along the axis A1. Moreover, although not required, the electromagnetic adhesive 26 may be co-extruded with the seal body 12. Co-extrusion of the seal body 12 and the electromagnetic adhesive 26 further reduces the complexity, cost, and manufacturing time of the seal assembly 10. The electromagnetic adhesive 26 may be co-extruded with the seal body 12 as a simple ribbon or as a plurality of discrete beads. It is to be appreciated that co-extrusion of the electromagnetic adhesive 26 with the seal body 12 may also apply the electromagnetic adhesive 26 to the seal body 12 continuously along the axis A1.
In the embodiments where the seal body 12 and the electromagnetic adhesive 26 are co-extruded, as shown in
However, it is also to be appreciated that the electromagnetic adhesive 26 may be formed separately, such as through extrusion, and later applied to the seal body 12 such that the electromagnetic adhesive 26 is applied to the seal body 12 continuously along the axis A1. As a non-limiting example, the electromagnetic adhesive 26 may be robotically applied to one or both of the seal body 12 and the molded component 24 after the seal body 12 has been extruded. It is to be appreciated that a water-tight seal may still be formed between the seal body 12 and the electromagnetic adhesive 26 even if the electromagnetic adhesive 26 is formed separately and later applied to the seal body 12.
Moreover, in the embodiments where the electromagnetic adhesive 26 is formed separately and later applied, the electromagnetic adhesive 26 may first be applied to the molded component 24. In other words, the electromagnetic adhesive 26 may be applied to the molded component 24, and the combined electromagnetic adhesive 26 and molded component 24 may then be applied to the seal body 12. The notch 42 may still be present on the seal body 12 to receive the adhesive 26 on the molded component 24. Alternatively, the molded component 24 may define a notch, and the electromagnetic adhesive 26 may be disposed in the notch on the molded component. The electromagnetic adhesive 26 may be disposed in the notch 42 either before softening, after softening, or both before and after softening. It is to be appreciated that the electromagnetic adhesive 26 may become disposed in the notch 42 upon softening. Moreover, the electromagnetic adhesive 26 may partially or fully fill the notch 42 upon softening. The electromagnetic adhesive 26 may be shaped to conform to the notch 42 when the molded component 24 is mounted to the seal body 12 (e.g., after softening). The electromagnetic adhesive 26 may be shaped to conform to the notch 42 as a result of the susceptor 30 softening the resin 28. However, it is to be appreciated that the electromagnetic adhesive 26 may be pre-shaped to conform to the notch 42 before the susceptor 30 softens the resin 28.
The molded component 24 may be molded separate from the seal body 12. In a non-limiting example, the molded component 24 may be molded through injection molding. The molded component 24 may even be over-molded onto the seal body 12 through injection over-molding. The molded component 24 may take many forms corresponding to many applications in the vehicle. As a non-limiting example, the seal assembly 10 may be further defined as an outer waist belt weatherstrip, which assists in functional sealing while also being aesthetically pleasing. In another non-limiting example, as shown in
Moreover, the decorative cover 50 may have a first cover portion 52 extending parallel to the first leg 16 of the seal body 12 and a second cover portion 54 extending at an angle from the first cover portion 52. The electromagnetic adhesive 26 may be disposed between the first cover portion 52 and the first leg 16. The angle may be between about 5 degrees and about 135 degrees, between about 10 degrees and about 90 degrees, between about 10 degrees and about 75 degrees, between about 10 degrees and about 60 degrees, between about 10 degrees and about 45 degrees, between about 10 degrees and about 40 degrees, or between about 15 degrees and about 35 degrees.
In one embodiment, as shown in
In another embodiment, as shown in
The seal body 12 may further include an embedded reinforcing member 58. The embedded reinforcing member may be for reinforcing the mounting channel 20 or otherwise stiffening the seal body 12. The embedded reinforcing member 58 may be comprised of a metal, a hard plastic, or any other material capable of reinforcing the structural integrity of the seal body 12.
The resin 28 may include a thermoplastic. In a non-limiting example, the resin 28 includes polypropylene. However, the resin 28 may include any combination of polyolefins, such as but not limited to polyethylene, polybutylene, polymethylpentene, olefin block copolymers, ethylene-octene copolymers, and propylene-butane copolymers. The molded component 24 may include thermoplastic olefin (TPO), such as but not limited to polypropylene, polyethylene, polybutylene, polymethylpentene, olefin block copolymers, ethylene-octene copolymers, and propylene-butane copolymers. The molded component 24 may also include acrylonitrile butadiene styrene (ABS) and polycaprolactone (PCL), or may include a thermoset material. The elastomeric material of the seal body 12 may include at least one chosen from a thermoplastic vulcanizate (TPV) and an ethylene propylene diene monomer (EPDM) rubber. In other words, the elastomeric material of the seal body 12 may include thermoplastic vulcanizate (TPV), ethylene propylene diene monomer (EPDM) rubber, or a combination of thermoplastic vulcanizate (TPV) and ethylene propylene diene monomer (EPDM) rubber. The elastomeric material of the seal body 12 may also include thermoplastic elastomer (TPE), thermoplastic olefin (TPO), thermoplastic polyurethane (TPU), or thermoplastic styrenic elastomers (TPS).
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.
The subject patent application claims priority to and all the benefits of U.S. Provisional Patent Application No. 63/343,796, which was filed on May 19, 2022, which is herein incorporated by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2023/022915 | 5/19/2023 | WO |
Number | Date | Country | |
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63343796 | May 2022 | US |