Patent Application
20200148048
The present disclosure generally relates to door carriers and associated forming methods, and more particularly to seals of door carriers for vehicles.
Vehicles, such as automobiles, include a plurality of door assemblies to allow entrance into and departure from the vehicle. The door assemblies may include a door frame and a door carrier disposed within the door frame, where a perimeter of the door carrier may be substantially surrounded by the door frame. To protect internal components of the door from environmental factors (e.g., water, debris, and dust), a seal may be provided around the perimeter of the door carrier. The seal may be formed of a resilient material such that the seal absorbs vibrations between the door frame and the door carrier during operation of the vehicle and so as to allow for manufacturing tolerances of the door frame.
The present disclosure provides a door carrier and a method for manufacturing the door carrier. The door carrier includes a body formed of a first material, where the body has an edge that extends around a perimeter of the body. The door carrier also includes a seal formed of a second material, where the seal is affixed to the edge of the body, such as via a chemical bonding of the seal when it is formed or injection molded at the edge of the body. The seal may extend away from the edge of the body, so as to space a distal end of the seal away from a proximal end that is affixed to the edge. The second material that forms the seal may be more resilient than the first material, such as, for example, a thermoplastic elastomer of the seal that has a lower durometer than a polypropylene used to form the body of the door carrier.
The edge of the body may extend continuously around the perimeter of the body of the door carrier, such that the seal may be affixed continuously to the edge around the perimeter of the body. The edge of the body may generally extend between and interconnect opposing first and second surfaces of the body. However, the body of the door carrier may include a portion that protrudes over the edge, such as a window rail that is integrated with the body of the door carrier. The protruding portion of the body may include a first surface of the body and an opposite side of the body may include a second surface. As such, at least a portion of the edge may be disposed between the first surface and the second surface, such as where the first surface of the protruding portion extends beyond the edge that receives the seal.
The seal may have a bend so as to define first portion extending along a first direction from the proximal end to the bend and a second portion extending along a second direction from the bend to the distal end at an angle relative to the first direction. The seal may have a length from the proximal end to the distal end, such as, for example, a length approximately between 5 mm and 15 mm. The seal may also have a thickness approximately between 0.5 mm and 2 mm.
The method for manufacturing the door carrier includes providing a tool or injection molding assembly that has a cover that encloses a portion of a cavity that forms the door carrier. A first tool or mold piece is provided at a spacing from and opposite the cover to at least partially define the cavity. A core back is slidably attached to the first tool to allow the core back to slide or move along a first direction between a retracted position and an engaged position that separates or restricts access to a portion of the cavity. To form a portion that protrudes over an edge of the body, another mold piece or lifter may be provided between the cover and the first tool. The method includes filling a first cavity with a first material to form a first piece. The method includes moving the core back along the first direction away from the lifter to expose a second adjacent cavity. The method includes filling the second cavity with a second material more resilient than the first material to form a second piece in contact with and bonded to the exposed edge of the first piece. The method further includes moving the first tool and the core back together along the first direction away from the cover, so as to permit the lifter to move along a second direction generally perpendicular to the first direction away from the first piece.
The step of moving the lifter along the second direction may include sliding the lifter against the second piece. Prior to moving the lifter along the second direction, the second piece may be in a first position. While moving the lifter along the second direction, the second piece may flex away from the lifter along the first direction to a second position. After moving the lifter along the second direction, the second piece may flex and substantially return to the first position. The material of the first piece may include a polypropylene and the second piece may include a thermoplastic elastomer (TPE) or similar material with thermoplastic or elastomeric properties.
These and other objects, advantages, purposes, and features of the present disclosure will become apparent upon review of the following specification in conjunction with the drawings.
Referring now to the drawings and the illustrative embodiments depicted therein, a door carrier 20 is generally shown that has a body 22 and a seal 24. The seal 24 is disposed at an edge 30 of the body 22 and extends around a perimeter of the body 22. The seal 24 is affixed to the edge 30 of the body 22, such as via a chemical bonding of the seal 24 when it is formed or injection molded at the edge 30 of the body 22. The seal 24 may extend away from the edge 30 of the body 22, so as to space a distal end 36 of the seal 24 away from a proximal end 34 that is affixed to the edge 30. The body 22 is formed of a first material and the seal 24 is formed of a second material that is substantially more resilient or with a lower durometer than the first material.
The perimeter of the door carrier 20 may be secured against or otherwise disposed at a frame component of a vehicle door, so as to place the seal 24 in contact with a perimeter portion of the frame component. It is contemplated that the door carrier may alternatively be disposed at a frame component of other portions of a vehicle frame. The frame component that receives the door carrier 20 may be partially exposed to an outside environment, including environmental factors such as water, debris, dust, mud, etc. The door carrier 20 may include a plurality of internal components. The seal 24 may provide the internal components with protection from environmental factors. Additionally, the seal 24 may provide a cushioning effect and may partially absorb vibrations between the frame component and the door carrier 20 while the vehicle is operated. Further, the seal 24 may absorb variations between the frame component and the door carrier 20.
With reference to
In a vehicle, there may be any suitable number of door carriers 20, such as, for example, two door carriers 20, four door carriers 20, etc. Each door of the vehicle may include a single door carrier, although it is contemplated that, alternatively, a single door may have a frame component that utilizes multiple door carriers. The body 22 of the door carrier 20 may include a first surface 26 and a second surface 28 opposite the first surface 26. In a fully-assembled vehicle, the first surface 26 may generally face an interior cabin of the vehicle and the second surface 28 may generally face an exterior environment. The first surface 26 and the second surface 28 may include a plurality of apertures, protrusions, depressions, or other formations to house or secure a plurality of internal components for a vehicle.
The body 22 of the door carrier 20 may include a portion or feature that protrudes over the edge 30, such as a window rail 32 that is at least partially integrated with the body 22. The protruding portion of the body 22 may include the first surface 26 of the body 22, such that at least a portion of the edge 30 may be disposed between the first surface 26 and the second surface 28, such as where the first surface 26 of the rail 32 extends beyond the edge 30. As one example, the rails 32 may be formed integrally with the body 22 using the same material. As another example, the rails or portions thereof may be formed separately from the door carrier and may be affixed or disposed adjacent to the body. The rails 32 may house window components, such as, for example, window regulators, motors, windows, etc.
The edge 30 of the body 22 may be disposed between the first surface 26 and the second surface 28. For example, the edge 30 may generally interconnect and extend from the first surface 26 to the second surface 28. The edge 30 may have a thickness approximately between 0.5 mm and 3 mm, such as to generally approximate the thickness of the body 22 or portion of the body 22 near the edge 30. It is also contemplated that the thickness of the edge may alternatively be more or less than this range, such as a thickness capable of providing a surface area sufficient to adhere to the seal 24. The edge 30 may extend continuously around the perimeter of the body 22. That is, the edge 30 may completely surround the body 22 in a generally planar configuration.
The body 22 may be formed of a first material, such as via injection molding in a single shot. The first material may be any suitable material, such as, for example, polypropylene, polyvinyl chloride, polyethylene, etc. As another example, the first material may be any suitable combination of the foregoing materials and may alternatively be formed with multiple injection shots of material.
With reference to
The seal 24 may include a bend 38 disposed between the proximal end 34 and the distal end 36. The seal 24 may include a first portion 40 extending from the proximal end 34 to the bend 38 along a first direction and a second portion 42 extending from the bend 38 to the distal end 36 along a second direction at an angle relative to the first direction. The angle between the first direction and the second direction may be approximately between 0 and 90 degrees. For example, the angle between the first direction and the second direction may be approximately between 30 and 60 degrees.
The first portion 40 may have a length L40 from the proximal end 34 to the bend 38. The second portion 42 may have a length L42 from the bend 38 to the distal end 36. The seal 24 may have a length L24 from the proximal end 34 to the distal end 36, i.e., the length L24 of the seal 24 may equal to the length L40 of the first portion plus the length L42 of the second portion 42. For example, the length L24 of the seal 24 may be approximately between 5 mm and 15 mm. Additionally, the seal 24 may have a thickness T24 generally equal to the thickness of the edge 30. For example, the thickness T24 of the seal 24 may be approximately between 0.5 mm and 2 mm or, alternatively, between 0.5 mm and 3 mm, or another alternative thickness dimension that is desired for the particular dimensions of the corresponding door carrier and associated vehicle application. Accordingly, the thickness T24 of the seal 24 may be adjusted for the corresponding durometer of the seal 24 material, such as a larger thickness of the seal 24 for a lower durometer and a thinner seal 24 for a higher durometer.
The seal 24 may be formed of the second material. The second material may be any suitable material, such as, for example, a plastic, a rubber, a thermoplastic elastomer, including styrenic block copolymers, thermoplastic polyolefinelastomers, thermoplastic vulcanizates, thermoplastic polyurethanes, thermoplastic copolyester, thermoplastic polyamides, etc. As another example, the second material may be any suitable combination of the foregoing materials. The second material is more resilient than the first material. That is, the second material has a second resilience greater than the first resilience. For example, the second material may be more flexible or less rigid than the first material. Also, the second material has a lower durometer than the first material.
With reference to
With reference to
The cover 52 may generally correspond to the first surface 26 of the body 22. The portion of the tool opposite the cover 52 or second part of the tool 54 may be spaced from and opposite the cover 52. The first tool 54 may generally correspond to the second surface 28 of the body 22. The core back 56 may be slidably attached to the first tool 54 along a first direction. That is, the core back 56 may slide back and forth along the first direction. The core back 56 may have a width approximately between 5 mm and 15 mm. The lifter 58 may be disposed between the cover 52 and the first tool 54. The cover 52, the first tool 54, and the lifter 58 may define a first cavity 60 therebetween. For example, the first cavity 60 may generally correspond to the body 22. When the core back 56 moves along the first direction away from the lifter 58, the body 22, the core back 56, and the lifter 58 may define a second cavity 62 therebetween. For example, the second cavity 62 may generally correspond to the seal 24.
In light of the foregoing, a method 70 for manufacturing the door carrier 20 will now be described with reference to
In step 74, the first cavity 60 is filled with the first material. The first cavity 60 may be filled by injection molding or any suitable process. For example, the first material may be heated until it melts, and then the melted first material may be injected into the first cavity 60 until the first cavity 60 is substantially filled. Then the melted first material may be cooled until the first material solidifies and forms a first piece, i.e., the body 22.
In step 76, the core back 56 may be slid relative to the first tool 54 along the first direction away from the lifter 58. At this point, the body 22, the core back 56, and the lifter 58 may define the second cavity 62 generally corresponding to the seal 24. The core back 56 may be moved along the first direction approximately between 0.5 mm and 3 mm, so as to generally correspond to the thickness of the seal 24.
In step 78, the second cavity 62 is filled with the second material. The second cavity 62 may be filled by injection molding or any suitable process. For example, the second material may be heated until it melts, and then the melted second material may be injected into the second cavity 62 until the second cavity 62 is substantially filled. Then the melted second material may be cooled until the second material solidifies and forms a second piece, i.e., the seal 24.
In step 80, the first tool 54 and the core back 56 are moved along the first direction away from the first piece, i.e., the body 22. The first tool 54 and the core back 56 may be moved simultaneously or separately from each other. In step 82, the lifter 58 is away from the first piece, i.e., the body 22. The lifter 58 is moved along a second direction generally perpendicular to the first direction. A portion of the lifter 58 may be disposed between the seal 24 and the rail 32 of the body 22. Because of the angle between the first portion 40 and the second portion 42 of the seal 24, the lifter 58 may slide along the seal 24, i.e., the second portion 42, as it moves along the second direction away from the body 22. The resilient nature of the seal 24 allows the seal 24 to flex as the lifter 58 slides along the seal 24. For example, prior to moving the lifter 58 along the second direction, i.e., between steps 80 and 82, the seal 24 is in a first position. While moving the lifter along the second direction, i.e., during step 82, the seal 24 flexes away from the lifter 58 along the first direction to a second position. After moving the lifter along the second direction, i.e., after step 82, the seal 24 flexes and returns to the first position.
In step 84, the part, i.e., the door carrier 20, is removed from the injection molding assembly 50 and the door carrier may then be used in any suitable application. For example, the door carrier 20 may be installed in a vehicle.
Referring now to
The cover 152 may generally correspond to the first surface 126 of the body 122. The portion of the tool opposite the cover 152 or second part of the first tool 154 may be spaced from and opposite the cover 152. The first tool 154 may generally correspond to the second surface 128 of the body 122. The accessory die piece 156, which may also be referred to as a core back, may be slidably attached to the first tool 154 along a first direction. That is, the accessory die piece 156 may slide back and forth along the first direction. The accessory die piece 156 may have a width approximately between 5 mm and 15 mm. The lifter 158, 159 may be disposed between the cover 152 and the first tool 154. The cover 152, the first tool 154, and the lifter 158, 159 may define a first cavity therebetween for forming the body 122 of the door carrier 120. For example, the first cavity may generally correspond to the body 122. When the accessory die piece 156 moves along the first direction on and toward from the lifter 158, 159, the accessory die piece 156 and the upper lifter 158 may define a second cavity 162 therebetween, such as shown in
As shown in
As shown in
As shown in
Referring now to
The cover 252 may generally correspond to the first surface 226 of the body 222. The portion of the tool opposite the cover 252 or second part of the first tool 254 may be spaced from and opposite the cover 252. The first tool 254 may generally correspond to the second surface 228 of the body 222. The core back 256 may be slidably attached to the first tool 254 along a first direction (
As shown in
As shown in
For purposes of this disclosure, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the orientation shown in
Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. The disclosure 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 disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.
This non-provisional U.S. patent application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application Ser. No. 62/758,838, filed Nov. 12, 2018, the disclosure of which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62758838 | Nov 2018 | US |
