Abstract:
A fixed pane window assembly is formed in a multicavity encapsulation method. Discrete and independent components are disposed in separate mold cavities. The mold cavities are filled and connected in sequence to form an intermediate body and subsequently an integral fixed pane window assembly incorporating a header trim strip, a division bar, and an incorporated fixed glass pane for cooperatively engaging a moveable window.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     None.  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not applicable.  
       REFERENCE TO A “SEQUENCE LISTING” 
       [0003]     Not applicable.  
       BACKGROUND OF THE INVENTION  
       [0004]     1. Field of the Invention  
         [0005]     The present invention relates to vehicle window assemblies, and more particularly to a method of forming a fixed pane window assembly having a header trim strip, a division bar and an encapsulated pane.  
         [0006]     2. Description of Related Art  
         [0007]     Many motor vehicles are constructed with a rear door having a forward window opening that carries a retractable, or movable window pane and a rearward window opening that is fitted with a fixed window pane. The fixed window pane, commonly referred to as a quarter light, quarter window or quarter panel, is typically required to avoid interference of the retractable window pane with the rear wheel well of the vehicle, when the retractable window pane is lowered. The larger movable window pane can be completely lowered to a fully open position, while the fixed window pane does not detract from visibility through the windows by the driver or the passengers.  
         [0008]     Because the movable window pane slides up and down relative to the adjacent fixed window pane, the molding or trim surrounding the fixed window pane must include a track or channel on a forward edge for slidable engagement with the movable window pane.  
         [0009]     Such interconnection requires relatively complicated structures encompassing a number of channels, fasteners and seals as well as secondary clips or fasteners which are employed to engage the components with the vehicle. These numerous parts and labor required to install the individual parts significantly contribute to the cost. In addition, the large number of components represents a source for construction flaws in manufacture as well as installation of the parts.  
         [0010]     Therefore, a need exists for a method of forming a fixed window assembly, wherein the resulting assembly includes a least a header trim strip, a division bar and an encapsulated glass. The need further exists for a method which can provide the fixed window assembly with molded materials optimized for the intended operating environment. The need also exists for a multicavity mold which allows for a sequencing of shots to provide for a substantially coincident cure or set time.  
       BRIEF SUMMARY OF THE INVENTION  
       [0011]     The present invention provides a method of forming a fixed pane window assembly, wherein the individual components are sequentially molded together to provide a one-piece fixed pane window assembly.  
         [0012]     In one configuration, a plurality of mold cavities are used to retain individual components of the assembly, wherein the mold cavities are sequentially filled and connected to form the one-piece fixed pane window assembly.  
         [0013]     Generally, the present method contemplates disposing at least one of the division bar, the header trim strip and the fixed pane into a first mold cavity and disposing at least one of a remaining one of the division bar, the header trim strip and the pane into a separate second mold cavity. A first polymeric material is then introduced into the first mold cavity to contact the at least one of the division bar, the header trim strip and the pane to form an intermediate body. The first mold cavity is then connected to the second mold cavity, and a second polymeric material is introduced into the second mold cavity to bond the intermediate body to the at least one of the remaining one of the division bar, the header trim strip and the pane. The present invention contemplates employing either similar or different first and second polymeric materials.  
         [0014]     It is further contemplated that more than two separate mold cavities can be employed in the present method. For example, each of the header trim strip, the division bar and the fixed pane can be disposed in a corresponding mold cavity. The respective mold cavities can be filled and connected in sequence to provide a resulting one-piece fixed pane window assembly. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)  
       [0015]      FIG. 1  is a perspective view of a motor vehicle incorporating a fixed pane window assembly of the present invention.  
         [0016]      FIG. 2  is a side elevational of view of a representative fixed pane window assembly.  
         [0017]      FIG. 3  is an exploded side elevational view of the header trim strip, division bar and fixed glass pane of the fixed pane window assembly of  FIG. 2 .  
         [0018]      FIG. 4  is a partial plan view of a plurality of separate mold cavities receiving respective components of the fixed pane window assembly. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     Referring to  FIG. 1 , an automotive vehicle  12  is shown, incorporating a fixed pane window assembly  20 . Although the fixed pane window assembly  20  can be operably employed in a variety of locations in the vehicle, the assembly is suited for providing an interface between a fixed pane  14  and a movable pane  16 . As seen in  FIG. 1 , the fixed pane window assembly  20  can be employed in a front or rear door of the vehicle. Further, the term “fixed pane” is intended to encompass quarter lights, panels or windows that can pivot, swivel or rotate relative to the frame assembly. For example, in one configuration of the assembly, the “fixed pane” can actually pivot to admit air between the pane and the frame. Thus, the fixed pane window assembly  20  encompasses front and rear door installations, wherein the assembly can employ a “fixed pane” which is fixed relative to the frame or pivots, swivels or rotates relative to the frame. For purposes of description, the formation of the fixed pane window assembly  20  is shown as a rear door, operably interconnecting the fixed pane  14  and the movable pane  16 .  
         [0020]     Referring to  FIGS. 2 and 3 , the fixed pane window assembly  20  includes a header trim strip  30 , a division bar  40 , and the fixed window pane  14 . The fixed window pane  14  is described in terms of a transparent or translucent glass pane. However, it is understood the fixed pane  14  can be an opaque member formed of any of a variety of materials including metals, composites and laminates, each of which is intended to be encompassed by the term pane.  
         [0021]     The header trim strip  30  is preformed, typically by an extrusion process. The header trim strip can be operably connected to a B-pillar  36 . Such connection to a B-pillar  36  is an optional configuration and not required in the present invention.  
         [0022]     The division bar  40  is connected to the fixed pane  14  and the header trim strip  30 , and engages a portion of the periphery of the movable pane  16 . Although the division bar  40  can have any of a variety of cross-sectional configurations, the division bar typically includes a fixed pane channel for receiving the fixed pane  14  and a movable pane channel for receiving the movable pane  16 .  
         [0023]     The fixed pane window assembly  20  also includes a glass encapsulation  50  formed of a polymeric material disposed about at least a portion of the periphery of the fixed pane  14 . Depending upon the intended connection of the encapsulated fixed pane  14  and the vehicle  12 , the glass encapsulation  50  can have any of a variety of configurations, without departing from the present invention.  
         [0024]     Although the fixed pane window assembly  20  is shown with only the header trim strip  30 , the division bar  40 , the fixed pane  14  and the glass encapsulation  50  (with the optional B-pillar  36 ), it is understood a beltline seal can also be incorporated with the fixed pane window assembly. In an alternative construction, it is contemplated the fixed pane window assembly  20  can include the division bar  40 , the fixed pane  14  and the beltline seal, wherein the header trim strip  30  can be subsequently added, connected or attached.  
         [0025]     The fixed pane window assembly  20  can include different polymeric materials in different areas so as to provide optimized performance characteristics. That is, in one configuration, the glass encapsulation  50  and bonding of the fixed pane  14  to the division bar  40  can be formed of a relatively hard polymeric material, while the interconnection of the header trim strip  30  and the division bar and fixed pane can be of a softer, more flexible polymeric material.  
         [0026]     The interconnection of the header trim strip  30  and the division bar  40  can include a sealing surface for forming a sealed interface with the movable pane  16 .  
         [0027]     Referring to  FIG. 4 , a multicavity mold is shown for forming the fixed pane window assembly  20 . In the configuration of  FIG. 4 , a first mold cavity  60  is formed in a first mold block  62 , wherein the first mold cavity is sized to receive a portion of the division bar  40  and the fixed pane  14 , and a second mold cavity  80  is formed in a second mold block  82 , wherein the second mold cavity is sized to receive at least a portion of the header trim strip  30 , with the B-pillar seal  36  being optionally connected to the header trim strip. The first mold cavity  60  is separated from the second mold cavity  80  by a movable shuttle or insert  70 . The insert  70  is movable between a cavity separating position and a cavity communicating position. Thus, the first mold cavity  60  is defined by a fixed portion and a movable portion (the insert  70 ). Similarly, the second mold cavity  80  is initially defined by a fixed portion and a movable portion, the insert  70 .  
         [0028]     As seen in  FIG. 4 , the insert  70  precludes communication between the first mold cavity  60  and the second mold cavity  80 . As the first mold cavity  60  and the second mold cavity  80  are separate, different polymeric materials can be injected into the respective cavities, each polymeric material generally optimized for the intended operating environment. The polymeric material employed in the mold cavities can include a selected polymer resin as well as fillers and additives typically employed in connection with the selected resin. The polymeric materials can be thermoset or thermoplastic, including, but not limited to EPDM, EDPM-SBR blends, polypropylene, polyethylene, polyurethanes, thermoplastic elastomers, thermoplastic vulcanizates, TPOs. Further, it is understood the polymeric material can be formed of only the selected polymeric resin, without additives or fillers.  
         [0029]     Preferably, the first mold cavity  60  is sized to encompass an exposed peripheral edge of the fixed pane  14  as well as a portion of the division bar  40 . Thus, introduction of a polymeric material encapsulates a periphery of the fixed pane  14 , as well as overlying a portion of the division bar  40 , thereby bonding the fixed pane to the division bar to form an intermediate body.  
         [0030]     The insert  70  is then moved from the cavity separating position to the cavity communicating position. The second mold cavity  80  is then defined by the fixed portion of the second mold cavity and an exposed portion of the intermediate body retained within the first mold cavity  60 .  
         [0031]     A polymeric material is then introduced into the second mold cavity  80  to bond the header trim strip  30  to the intermediate body. The polymeric material introduced into the second mold cavity  80  can be the same as a polymeric material introduced in the first mold cavity  60 . Alternatively, the polymeric materials employed in the first and second mold cavity  60 ,  80  can be different, each optimized to provide desired operating characteristics of the corresponding portion of the fixed pane window assembly  20 .  
         [0032]     Employing different polymeric materials in the first and second mold cavity  60 ,  80  can result in different set or cure times for the respective mold cavity. The set or cure time for a polymeric material in the given mold cavity is partially determined by the volume of the polymeric material within the mold. Typically, the larger the volume of material, the longer the set or cure time. Therefore, it is contemplated to size the first mold cavity  60  and the second mold cavity  80  such that the amount of polymeric material received within the respective mold cavity provides a substantially coincident termination of residence time within the respective cavity.  
         [0033]     For example, in the mold shown in  FIG. 4 , the first mold cavity  60 , retaining the fixed pane  14  and the division bar  40 , retains a larger volume of polymeric material than the second mold cavity  80  retaining the header trim strip  30 . In operation, the first mold cavity  60  is filled first and begins curing/setting. A period of time is allowed for the polymeric material in the first mold cavity  60  to sufficiently set to preclude flow into the second mold cavity  80  upon movement of the insert  70 . Further, the intermediate body thus formed in the first mold cavity  60  retains a fixed position within the first mold cavity, during filling of the second mold cavity  80 . The insert  70  is moved to the cavity communicating position and the polymeric material introduced into the second mold cavity  80 , such that the polymeric material contacts the intermediate body of the first mold cavity. The volume of the polymeric material in the second mold cavity  80 , being less than the volume of polymeric material in the first mold cavity  60 , has a shorter set or cure time. Preferably, the required residence time of the polymeric material in the second mold cavity  80  is sufficiently shorter than the polymeric material in the first mold cavity  60 , such that upon the polymeric material in the first mold cavity being sufficiently stable for opening of the mold, the polymeric material in the second mold cavity is also sufficiently stable for opening of the mold.  
         [0034]     However, it is understood the introduction of the first polymeric material, the coupling of the first and second mold cavities and the introduction of the second polymeric material can be a substantially uninterrupted sequence. That is, immediately after introducing the first polymeric material, the mold cavities can be connected and immediately following, the second polymeric material can be introduced into the second mold cavity. Thus, depending upon the selected polymeric materials, the interface between the polymeric materials of the first and second mold cavities can be controlled. Therefore, the sequencing in the present process can be immediate, or delayed wherein the delay between the steps can be on the order or seconds, minutes or hours.  
         [0035]     Preferably, the interface between the intermediate body and the polymeric material introduced into the second mold cavity provides a bonded connection. That is, the polymeric material introduced into the second mold cavity bonds to the previously introduced polymeric material in the first mold cavity. It is also preferred the polymeric material of the second mold cavity also bond to any contacted portions of the division bar  40  or the fixed pane  14 .  
         [0036]     In addition, the timing of the introduction of the polymeric materials is selected to enhance bonding of the polymeric material in the second mold cavity  80  to the intermediate body.  
         [0037]     Generally, the present method includes disposing at least one the division bar  40 , the header trim strip  30  and the fixed pane  14  into a first mold cavity  60 ; disposing at least one of a remaining one of the division bar, the header trim strip and the pane into a separate second mold cavity  80 ; introducing a first polymer resin into the first mold cavity to contact the at least one of the division bar, the header trim strip and the fixed pane to form an intermediate body; interconnecting the first mold cavity and the second mold cavity; and introducing a second polymer resin into the second mold cavity to bond the intermediate body to the at least one of the remaining one of the division bar, the header trim strip and the fixed pane.  
         [0038]     Although the method is described in terms of the first mold cavity  60  and the second mold cavity  80 , as seen in  FIG. 6  it is contemplated that a third mold cavity  100  can be employed wherein each mold cavity retains one of the header trim strip  30 , the division bar  40  and the fixed pane  14  of the window assembly  20  and are initially separate and distinct. In such configuration, the molds  60 ,  80 ,  100  are selectively interconnected after injecting a polymeric material into the respective mold cavity, thereby forming a first intermediate body and a subsequent second intermediate body. This method can provide for further optimization of the polymeric material for the corresponding portion of the fixed pane window assembly  20 .  
         [0039]     Therefore, the present method provides a fixed window pane assembly for a motor vehicle, having a one piece molding joining the header trim strip  30 , a division bar  40  and a pane  14 , the molding encapsulating at least a portion of a periphery of the pane and bonding the division bar with the first polymeric material for defining an intermediate body; and the one piece molding bonding the header trim strip  30  to the intermediate body with a different second polymeric material.  
         [0040]     It is further contemplated the volume of the first polymeric material and the volume of the second polymeric material are selected to provide a stable assembly upon a concurrent or simultaneous opening of the first mold cavity and the second mold cavity.  
         [0041]     While the invention has been described in connection with a presently preferred embodiment thereof, those skilled in the art will recognize that many modifications and changes can be made without departing from the true spirit and scope of the invention, which accordingly is intended to be defined solely by the appended claims.