Vehicle door molding structure

A vehicle door molding structure includes: a variable molding formed integrally along an upper edge of a vehicle door, where a width of the variable molding varies along a length thereof; and an insert molded part connected to an upper part of the variable molding along a height of a vehicle, where a lower part of the variable molding along the height of the vehicle is attached to the vehicle door with adhesion tape.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims under 35 U.S.C. §119(a) the benefit of Korean Patent Application No. 10-2015-0099876 filed in the Korean Intellectual Property Office on Jul. 14, 2015, the entire contents of which are incorporated herein by reference.

BACKGROUND

(a) Field of the Invention

The present invention relates to a vehicle door molding structure, and more particularly, to a vehicle door molding structure that is installed along an upper edge of the vehicle's rear door and can improve aesthetic appearance.

(b) Description of the Related Art

Conventional vehicle frame doors have a structure in which a door inner panel and a door outer panel combine together to form a door frame structure, and a door frame forming a door window is connected onto the door inner panel and the door outer panel. Such vehicle frame doors are advantageous in terms of weight and cost, but there are drawbacks such as corrosion or deterioration in aesthetic appearance.

Typically, a door molding made of stainless steel is attached to a door frame along an upper edge, in order to improve the aesthetic appearance of the door.

Especially in the case of a rear door, a variable molding, whose width varies along a length of the vehicle, is attached to the upper edge of the door frame, in order to improve the door's aesthetic appearance.

The door frame is typically made of metal in a given shape, and the variable molding is made of stainless steel in a variable shape whose width varies along the length of the vehicle. Thus, the variable molding has an insert molded part made of plastic to connect the variable molding and the door frame, and the insert molded part is bonded to the door frame with adhesion tape.

Also, a door weatherstrip is mounted on the door frame through a lift molding. The shape of the lift molding varies according to variation in the width of the variable molding.

In conjunction with a conventional vehicle door molding structure with an attached variable molding, there is a demand for higher strength for connection between the door frame and the variable molding to prevent the variable molding from coming off or falling out, with the aim of improving and maintaining the aesthetic appearance of the vehicle's door.

SUMMARY

The present invention provides a vehicle door molding structure that is capable of improving the aesthetic appearance of a vehicle door, keeping a variable molding stably attached to a door frame, and achieving weight and cost reductions.

An exemplary embodiment of the present invention provides a vehicle door molding structure including: a variable molding integrally coupled to an upper edge of a vehicle door, wherein a width of the variable molding varies along a length thereof; and an insert molded part connected to an upper part of the variable molding along a height of a vehicle, wherein a lower part of the variable molding along the height of the vehicle may be attached to the vehicle door with adhesion tape.

The vehicle door may include a door frame forming a door window, wherein the variable molding may be connected to the door frame.

The door frame may have a mounting flange that is positioned in an outer side of a width of the vehicle, positioned in an upper part of the height of the vehicle, and extends along the length of the vehicle, wherein the variable molding may be attached to the mounting flange with the adhesion tape.

The door frame may include an upper connecting recess opened upwards along the height of the vehicle, wherein a lift molding may be connected to the upper connecting recess, and a door weatherstrip may be connected to the lift molding. The door frame may include a lower connecting recess opened downwards along the height of the vehicle, a glass run molding may be connected to the lower connecting groove. The glass run molding may have a connecting recess depressed inwards along the width, and the door frame may have a connecting boss that is inserted and connected into the connecting recess.

A lower hook, bent inwards along the width of the vehicle, may be formed integrally on a lower end of the variable molding along the height of the vehicle, and the glass run molding may have a receiving recess where the lower hook is received.

Nonwoven fabric may be attached to the lower hook.

The lower hook may protrude at a protrusion height from a bottom surface of the door frame.

The protrusion height may be preferably 0.2 mm or greater.

A receiving recess for receiving an upper part of the mounting flange may be formed at the bottom of the lift molding along the height of the vehicle, and the receiving recess may include an inner protrusion positioned in an inner side of the width of the vehicle and an outer protrusion positioned in the outer side thereof, wherein the outer protrusion may be shaped like a triangle that becomes narrow downwards along the height of the vehicle.

When the variable molding may be bonded and connected to the door frame, the outer protrusion may overlap the mounting flange.

At least one upper hook may be provided in the upper part of the variable molding along the height of the vehicle and inserted into the insert molded part.

An end piece may be connected to either end of the length of the variable molding and the insert molded part.

The end piece may include: a piece body having a polygonal shape; a hook slot formed at a rear part of the length of the piece body and at a lower part of the height of the piece body; a stopper formed at a rear part of the length of a top edge and protruding upwards along the height of the piece body; and an end rim formed at the rear end of the length of the piece body and sloping upward along the height of the piece body and forwards along the length of the piece body.

A hook may be provided on either end of the length of the variable molding and inserted and connected into the hook slot of the end piece.

When the end piece is connected to the insert molded part, the top edge of the piece body may be inserted and received in the insert molded part, and a bottom edge of the insert molded part along the height of the insert molded part may overlap the top edge.

When the end piece is connected to the insert molded part, the stopper and end rim of the end piece may be in contact with the rear end of the insert molded part, thereby preventing the insert molded part from moving longitudinally.

The lift molding may be assembled to the door frame through one or more water-resistant clips.

Each water-resistant clip may include: a cylindrical clip body; a clip head portion formed at the forepart of the clip body and having a larger diameter than the clip body; and a water-resistant flange extending radially from the clip body to block an assembly hole of the door frame when the water-resistant clip is inserted and fastened into the assembly hole of the door frame.

In a vehicle door molding structure according to an embodiment of the present invention, the variable molding is attached to the door frame with adhesion tape and the lower end of the variable molding along the height of the vehicle is stuck in the door frame. Hence, the variable molding can be kept stably attached to the door frame, thereby preventing the variable molding from coming off or falling out and improving the aesthetic appearance of the vehicle's door.

The variable molding and the insert molded part are combined together, and a plurality of hooks formed on the variable molding increase the strength of connection between the variable molding and the insert molded part, thereby preventing the variable molding and the insert molded part from being separated from each other.

Since the glass run molding fitted into and attached to the door frame has a recess and the door frame to be inserted into the recess has a boss, the strength of connection between the glass run molding and the door frame can be increased. Therefore, the noise, vibration, and harshness (NVH) performance of the vehicle and the aesthetic appearance of the vehicle door can be improved.

A pressure-resistant projection can be formed on the insert molded part for use when the variable molding is inserted into a mold for insertion molding. Therefore, it is possible to avoid surface sinks on the variable molding caused by the mold core, which are produced when the variable molding with which the insert molded part is formed is taken out of the mold.

It is possible to prevent the end piece from falling out because the end piece is connected to both the variable molding and the insert molded part.

Since two opposite ends of the lift molding are assembled to the door frame through water-resistant clips, this prevents corrosion caused by moisture intrusion or the like, thereby improving durability and aesthetic appearance.

Moreover, the reduction in the size of the insert molded part can lead to reductions in weight and cost and improve the overall assemblability of the molding structure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring toFIG. 1, a vehicle door molding structure according to the exemplary embodiment of the present invention preferably includes a variable molding20attached to an upper part of a vehicle door10.

The variable molding20may vary in width along the length of the vehicle. That is, the width W of a front part of the variable molding20along the length of the vehicle may be smaller than the width W1of a rear part thereof.

The width of the variable molding20may increase, for example, linearly towards the rear part from the front part.

Such a variable molding20may serve to improve the aesthetic appearance of the vehicle door.

Referring toFIG. 2, the vehicle door10may include a door frame12forming a door window. The door frame12may have a mounting flange122with a substantially rectangular shape that is positioned in an outer side of a width of the vehicle, positioned in an upper part of a height of the vehicle, and extends along a length of the vehicle.

The variable molding20may be bonded to the mounting flange122with adhesion tape30. The width of the variable molding20is larger than the width of the mounting flange122. When the variable molding20is bonded to the mounting flange122, the mounting flange122is bonded to part of an inner side of the variable molding20.

An upper part of the variable molding20along the height of the vehicle may be connected to an insert molded part22, and a lower part of the variable molding20may be bonded to the door frame12with adhesion tape30. The above door frame bonding structure having the variable molding20and the adhesion tape30can enhance the adhesion of the variable molding20to the door frame12, prevent a reduction in adhesion due to deformation of the insert molded part22, and improve the workability of the bonding process, as compared with the conventional method in which the adhesive tape30is attached to the insert molded part22to bond the variable molding20to the door frame12.

The door frame12may include an upper connecting recess124with a substantially U-shape cross-section, opened upwards along the height of the vehicle, and a lower connecting recess126positioned lower than the upper connecting recess124along the height of the vehicle and opened downwards along the height of the vehicle.

A lift molding40may be connected to the upper connecting recess124, and a door weatherstrip50may be connected to the lift molding40. The door weatherstrip50is placed between a vehicle body60and the door10when the door10is closed, to maintain airtightness between them.

Two opposite ends of the length of the lift molding40may be assembled to the door frame12through water-resistant clips90.

A glass run molding70may be inserted and connected into the lower connecting recess126. The glass run molding70is in tight contact with a window glass80to maintain water resistance and airtightness.

To increase the strength of connection between the glass run molding70and the door frame12, the glass run molding70may have a connecting recess72depressed inwards along the width, and the door frame12facing the connecting recess72may have a connecting boss128that is inserted and connected into the connecting recess72.

The connecting recess72and the connecting boss128may serve to keep the glass run molding70in position when the window glass80presses against the glass run molding79as it is inserted into the glass run molding70. Also, the connecting recess72and the connecting boss128may serve to absorb manufacturing tolerance generated during the manufacture of the glass run molding70or variable molding20, and therefore the noise, vibration, and harshness (NVH) performance of the vehicle and the aesthetic appearance of the vehicle door can be improved.

Referring toFIG. 3, a substantially U-shaped lower hook202, bent inwards along the width of the vehicle, may be formed integrally on a lower end of the variable molding20along the height of the vehicle, and the glass run molding70may have a receiving recess74where the lower hook202is received.

Nonwoven fabric24may be attached to the lower hook202to prevent injury during assembling.

The lower hook202protrudes at a protrusion height T from a bottom surface129of the mounting flange122. Thus, when the variable molding20is connected to the door frame12, the lower hook202preventing the variable molding20from easily falling sideways out of the door frame12along the width of the vehicle.

The protrusion height T is preferably 0.2 mm or greater.

Referring toFIG. 4, a receiving recess222for receiving an upper part of the mounting flange122of the door frame12may be formed at the bottom of the lift molding22along the height of the vehicle, and the receiving recess222may be formed of an inner protrusion223positioned in the inner side of the width of the vehicle and an outer protrusion224positioned in the outer side thereof.

The outer protrusion224may be formed in a substantially triangular shape (i.e., shaped like a triangle) that becomes narrow downwards along the height of the vehicle. When the variable molding20is bonded and connected to the door frame12, the outer protrusion224may overlap the mounting flange122.

Typically, the variable molding20made of stainless steel and the insert molded part22made of plastic are combined together. To combine the insert molded part22and the variable molding20together, the variable molding22is inserted into an injection mold and held in place. Then, plastic resin is injected into the mold to form the insert molded part22. Afterwards, when the core is removed to take the variable molding20and the insert molded part22out of the mold, surface sinks may be produced as the variable molding20is pressed against the core. Since the outer protrusion224is positioned where the variable molding is pressed against the core, surface sinks on the variable molding20can be avoided.

Referring toFIG. 5, a substantially U-shaped upper hook204, bent inwards along the width of the vehicle, may be provided in the upper part of the variable molding20along the height of the vehicle.

A plurality of upper hooks204may be formed at predetermined intervals along the length of the variable molding20.

The plurality of upper hooks204may be inserted into the insert molded part22.

The plurality of upper hooks204make the variable molding20and the insert molded part22firmly attached together, thereby preventing the insert molded part22and the variable molding220from being separated from each other or falling out.

The lift molding40may be bonded to the door frame12with the adhesion tape30.

Referring toFIG. 6andFIG. 7, an end piece100may be connected to either end of the length of the variable molding20and the insert molded part22.

The end piece100may include a piece body101having a polygonal shape, a hook slot102formed at a rear part of the length of the piece body101and at a lower part of the height of the piece body10(preferably, at the same time), a stopper104formed at a rear part of the length of a top edge103and protruding upwards along the height of the piece body101, and an end rim106formed at the rear end of the length of the piece body101and sloping upward along the height of the piece body101and forwards along the length of the piece body101.

A hook206may be formed integrally on either end of the length of the variable molding20and protrude from them.

With the insert molded part22and the variable molding combined together, when the end piece100is connected to the rear ends of the variable molding20and insert molded part22, the hook206of the variable molding20is inserted and connected into the hook slot102of the end piece100, thereby increasing the strength of connection between the end piece100and the variable molding20.

The top edge103of the end piece100is inserted and received in the insert molded part22, and a bottom edge225of the insert molded part22along the height of the insert molded part22overlaps the top edge103, thereby increasing the strength of connection between the insert molded part22and the end piece100by interlocking.

Moreover, the stopper104and end rim106of the end piece100are in contact with the rear end226of the insert molded part22, thereby preventing the insert molded part22from moving longitudinally.

Referring toFIG. 8, the water-resistant clips90are assembled to two opposite ends of or multiple parts of the length of the lift molding40. Thus, the lift molding40may be fastened and supported onto the door frame12through the water-resistant clips90.

Each water-resistant clip90may include a cylindrical clip body92, a clip head portion94formed at the forepart of the clip body92and having a larger diameter than the clip body92, and a water-resistant flange96extending radially from the clip body92to block an assembly hole of the door frame12when the water-resistant clip90is inserted and fastened into the assembly hole of the door frame12.

Since the lift molding40is bonded to the door frame12with the adhesion tape30and also fastened to the door frame12through multiple water-resistant clips90, the fastening power is increased. Also, the water-resistant flange96prevents the intrusion of foreign materials such as moisture into the assembly hole of the door frame12. This prevents corrosion of the door frame12, thereby improving durability and avoiding deterioration in aesthetic appearance. In addition, reference numeral32is a release agent coated onto the adhesion tape30.