OUTER BELT WITH MOLDED SNAP-FIT RETENTION FEATURE

A belt seal assembly is provided for an associated vehicle. The belt seal assembly includes a first leg and a second leg interconnected at one end by a base to form an inverted, generally U-shaped body. A seal lip extends outwardly from an outer face of the first leg that is configured to slidably, sealingly engage an associated window surface of the associated vehicle. A tab extends from the body and is dimensioned to be received in snap-fit relation with an associated opening of an associated outer door panel. The tab includes a hard retaining insert received in a more flexible overmold that forms an end cap. A protrusion extending from the retaining insert snap-fits with an opening in the associated vehicle door panel. The belt seal assembly can also be removed from the vehicle for servicing.

BACKGROUND

The present disclosure relates to a seal assembly that is also referred to in the automotive industry as a weatherstrip, weatherseal, or seal assembly, and more particularly a weatherseal assembly used in connection with a vehicle. The weatherseal assembly of the present disclosure specifically relates to what is known as a vehicle belt assembly that is provided along a lower edge of a window opening formed in a door of the vehicle, and more specifically an outer belt assembly.

Belt seal assemblies are generally known in the art. For example, commonly owned patents and published applications U.S. Pat. No. 10,946,735 (Exhibit A); U.S. Pat. Nos. 4,949,507; 5,207,027; 5,493,815; 5,618,593; US 2005/0235569A1; and WO2009/143250A1 are representative of other belt seal assemblies, and the entire disclosure of each is expressly incorporated herein by reference.

A need exists for an improved outer belt weatherseal assembly that is cost effective, that is easy to manufacture, conducive to assembly on a vehicle door, improves retention of the outer belt, and that includes a feature allowing the assembly to be easily removed for service.

SUMMARY

The present invention discloses an outer belt assembly that includes an end mold with a snap-fit insert retention feature to advantageously secure the outer belt assembly to an associated vehicle door, and that is also configured for ease of serviceability.

In one embodiment, the configured retention feature includes a positive locating feature for receiving and aligning an associated removal tool to disengage the insert retention feature from engagement with the associated vehicle door.

The configured retention feature in one embodiment may include a v-shaped groove to receive and guide the associated removal tool and disengage the retention feature, and in another variation, the configured retention feature includes an opposing tab that is adapted to be engaged by the associated removal tool for serviceability of the outer belt assembly.

This disclosure eliminates the need to package a screw or dictate original equipment manufacturer (OEM) installation procedure.

The present disclosure allows the outer belt assembly to be slid into place and an integrated retention feature advances into an engaged position to advantageously secure the outer belt assembly to an associated vehicle door along a belt line of an associated opening in the vehicle door.

The outer belt assembly cannot be removed without deactuating the retention feature, such as a protrusion, from locking engagement with the associated vehicle door.

The assembly can also be easily serviced without breaking the retention feature.

Other than for servicing, the outer belt assembly of the present disclosure includes a fully integrated retention feature, shoulder, or clip that requires no tools and no auxiliary fasteners to secure the outer belt assembly in place.

The present disclosure can be advantageously used for so-called frameless vehicles, and can also be used in connection with a frame-under-glass vehicle construction.

The outer belt assembly may be installed with the window (glass) in place or without the window in place, while prior art arrangements usually require the window to be in place when mounting the outer belt assembly.

Still other benefits and advantages of the present disclosure will become more apparent from reviewing and understanding the following detailed description and drawings.

DETAILED DESCRIPTION

FIGS.1-3illustrate the present invention of a weatherseal assembly100, particularly an outer belt assembly, in an exploded, unmounted view ofFIG.1and assembled to an associated vehicle door V that includes a first or inner door panel V1and a second or outer door panel V2that are joined together along a vehicle door flange VDF as shown inFIGS.2and3. The outer belt assembly100includes an extrusion portion or body102having a generally inverted U-shaped configuration formed by a first or inner leg104connected to a second or outer leg106by an interconnecting base108. The extrusion portion or body102of the illustrated embodiment typically includes a carrier or core110(e.g., metal, wire, and/or plastic) that is preferably at least partially encapsulated by an extruded material such as EPDM, TPV, and/or TPE, although this list of preferred extrusion materials should not be deemed limiting.

With continued reference toFIG.1, and additional reference toFIGS.2-3, at least a first sealing lip120extends outwardly from the extruded body102(i.e., outwardly from an outer surface of the first leg104and in a direction away from the second leg106) toward the window (glass) W. The first sealing lip120may include a flock, or a low friction material or coating that reduces friction between the at least first sealing lip and a surface of the window W during relative movement between the sealing lip(s) and the window when the window is raised and lowered. Further, at least one gripping member122, and preferably first and second gripping members122a,122bextend from the second leg106of the body102in a direction toward the first leg104. The at least first sealing lip120and the gripping members122preferably extend along the length of the body in order to seal against the window W and secure the outer belt assembly100along the length of the vehicle door flange VDF, respectively.

There is shown inFIG.2a portion of the associated vehicle door (door) V with a window opening. As is well known, the window (glass) W moves upwardly and downwardly in the door V to selectively close the window opening in an upper, raised position, and provide an opening in the door in a lowered position. The door outer panel V2has a conformation that forms a recess124that extends laterally inwardly toward the flange, and the recess receives a show portion (outer surface of the second leg106of the body102of the outer belt assembly (extrusion)100as illustrated inFIG.3when the extrusion is mounted on the vehicle door V.

A retention feature is also shown inFIG.1and includes an overmold130and a retaining insert132. The overmold130is a portion of and configured to serve as an end cap134of the assembly that is received in an end of the extrusion. Preferably the overmold130/end cap134has a planar end face136that is contoured to cover a terminal end of the U-shaped extrusion102. Extending axially from the planar end face136of the overmold130is a longitudinal portion138that has a downturned finger or tab150at an opposite end of the overmold from the planar end face. The downturned tab150receives the insert or retaining insert132(preferably the overmold130is formed (overmolded) over at least part of the retaining insert). The retaining insert132preferably has a limited longitudinal or axial length (a slightly narrower longitudinal width than a longitudinal width of the tab150) and the retaining insert in one arrangement preferably has generally planar opposite faces152,154. First and second protrusions156,158extend outwardly from the opposite, planar faces of the insert. The first or upper protrusion156has a curved outer contour160that facilitates snap-fit receipt of the upper protrusion through an associated slot or opening O in the vehicle door (e.g., in the inner panel V1of the vehicle door V—FIGS.2and3) when the outer belt assembly100is mounted over the door flange VDF. The slot/opening O provided in the door flange V1is preferably adjacent at least one longitudinal end near a vehicle pillar (e.g., B pillar) so that the slot/opening receives the first or upper protrusion156(illustrated as extending outwardly from the planar surface152(left-hand surface of the retaining insert132and the overmold130that encases the retaining insert and preferably spaced along a longitudinal extent of the flange) at a transition region between the tip and the remainder of the flange.

An upturned lip or shoulder170at the upper, outer edge of the upper protrusion156prevents inadvertent removal of the upper protrusion from the vehicle door slot/opening O once the upper protrusion has been received therein. The second or lower protrusion158preferably extends from the opposite face154of the retaining insert132. The lower protrusion158also includes an upturned lip or shoulder172at a terminal end, and the upturned lip/shoulder of the retaining insert132is spaced from the surface of the overmold130by a limited dimension that is adapted to receive a flat or planar tool surface such as a screwdriver, putty knife, or spatula therein, for servicing, i.e., removal, of the outer belt assembly100from the vehicle door V if required for servicing such as repair or replacement. To achieve this, a trim panel (not shown) would be removed from the door V, a downward force exerted on the outer belt assembly100, and then the lower tab158engaged by a flat screwdriver/spatula or similar tool to separate the outer belt assembly from the flange opening O (i.e., the tool would engage the shoulder172of the lower protrusion158, and the shoulder170of the upper protrusion156removed from the opening O in the inner door panel V1).

The cross-sectional views ofFIGS.2-3are taken along the belt assembly100. These figures exhibit a structural profile of the body102of the outer belt seal assembly100that can be easily extruded/coextruded for ease of manufacture and the integrated overmold130/retaining insert132/end cap134is then inserted into a terminal end of the extruded/coextruded body102. The weatherseal assembly100is preferably extruded from an elastomeric material that includes, for example, commonly used weatherstrip materials such as EPDM (ethylene propylene diene monomer rubber), TPE (thermoplastic elastomer), and/or TPV (thermoplastic vulcanizate) material, although this list of preferred materials should likewise not be deemed limiting since it is understood that other materials or combinations of materials can also be used. As noted above, at least a portion of the weatherseal assembly100is oftentimes reinforced with a carrier or core110, for example, with a steel, aluminum (or possibly a hard plastic core), and/or a wire carrier that is completely or partially encapsulated through the co-extruded manufacturing process. Again, this structural and manufacturing preference should not be construed as the only way to assemble or manufacture the weatherseal assembly100. The overmold130and the retaining insert132are preferably a molded plastic construction. In a preferred arrangement, the overmold130/end cap134is a TPV, while the retaining insert132is a harder, less flexible, plastic material such as a glass filled nylon. Again, the preferred materials of the end cap134/overmold130and retaining insert132should not be deemed limiting since it is understood that other materials or combinations of materials can also be used without departing from the scope and intent of the present disclosure.

FIGS.4-10illustrate another embodiment, that includes modifications from that version of the present disclosure described in connection withFIGS.1-3. For ease of illustration and understanding, and for purposes of brevity, like reference numerals in the “200” series will be used to refer to like components in the embodiment ofFIGS.4-10that were previously described in connection withFIGS.1-3. For example, the weatherseal/outer belt assembly inFIGS.4-10will be generally identified by reference numeral200while the weatherseal/outer belt assembly ofFIGS.1-3used reference numeral100. Where possible, new reference numerals will be used to identify new components.

Body202exhibits the same structural features and functions as the body102associated with the previous embodiment. The body202includes a first or inner leg204joined to a second or outer leg206by an interconnecting base208. The body202may include a carrier or core210, and includes one or more sealing lips220that extend outwardly for engagement with a window W, and one or more gripping members222that grippingly engage an associated vehicle door flange VDF to mount the body to the associated vehicle door V.

More particularly, weatherseal/outer belt assembly200inFIG.4is believed to be an improvement over the assembly100ofFIGS.1-3for at least the following noted differences. For example, overmold230is still incorporated into an end cap234. The end cap234includes a substantially planar face236that abuts against the end of the body202. On a front door, the end cap234is received at the B pillar (typically the outer belt assembly is secured via a fastener (e.g., screw) at the A pillar). On a rear door, end caps234such as described herein can be used at one or both ends (B and C pillars) of the outer belt assembly200to close out terminal ends of the body202, and to secure the outer belt assembly200to the vehicle door V.

Tab250incorporates a locating feature280to positively guide an associated tool (not shown). A preferred configuration of the locating feature280is a V-shaped recess along a bottom surface of the tab250. As will be appreciated, a tool such as a J-shaped fishhook may be advanced past seal lip220so that the J-shaped fishhook end is received in the V-shaped recess280. By pulling upwardly and rocking the tool, the tab250and particularly retaining insert232can be removed from the opening O in the inner door panel V1to facilitate extraction of shoulder270from the door panel opening. As evident from a comparison ofFIGS.1and4, the retaining insert232includes only one protrusion, namely protrusion256extending outwardly from face252of the retaining insert. Because of the locating feature280, there is no need for a second protrusion in this modified embodiment as described in the embodiment ofFIGS.1-3. The retaining insert232is similarly configured with a V-shaped recess282that conforms to the shape and location of locating feature280of the tab250.

In addition, the protrusion256(FIG.4) is formed as a pair of gussets rather than a solid block as used in the embodiment ofFIGS.1-3. Curved surfaces260on the gussets facilitate guidance of the protrusion256into the opening O in inner door panel V1. Likewise, the curved surfaces260also prevent breaking of the protrusion256during the extraction process.

As is the case in the prior embodiment, the arrangement ofFIG.4preferably forms the end cap234/overmold230of a more flexible material (e.g., TPV) than the harder, less flexible glass filled nylon preferably used in the construction of the retaining insert232.

Installation of the outer belt assembly100,200also provides a feedback to the installer when the hard retaining insert shoulder270snaps into place in the vehicle door panel opening O. The more flexible material used in the end cap234allows that end of the outer belt assembly202to flex during installation. Once installed, there is no requirement of an additional pushpin, rivet, secondary fastener, adhesive, tape, etc. used to secure the end of the outer belt assembly200in place.

By removing the second protrusion in the embodiment ofFIGS.4-10, there is less chance for potential scratching of the window W since there is no protrusion from the side of the tab250and retaining insert232that face the window.

To facilitate manufacture of the tab250and the retaining insert232, central openings290,292, respectively, are provided therein and align with one another when the overmold material of the end cap is molded over the retaining insert. The openings290,292facilitate manufacture of the molded arrangement by allowing tool components to slide or pass therethrough.

The concepts of the present disclosure are shown relative to an outer belt seal assembly, but may also find application in connection with the inner belt seal assembly without departing from the scope and intent of the present disclosure.

This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope of the disclosure may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the present invention if they have structural elements that do not differ from the literal language hereof, or if they include equivalent structural elements with insubstantial differences from the literal language of this disclosure. Moreover, this disclosure is intended to seek protection for a combination of components and/or steps.