Vehicle weather strip for liquid drainage and prevention of liquid intrusion into vehicle interior

A weather strip for a vehicle door includes a flow channel extending along at least a portion of the weather strip. A discharge portion is in fluid communication with the flow channel and is structured to enable a liquid to flow therealong from the flow channel to a location outside the flow channel. An end wall extends from a first side of the flow channel and is positioned to direct a liquid impinging on the end wall from the flow channel toward the discharge portion.

TECHNICAL FIELD

The present invention relates to weather strips for vehicle doors and, more particularly, to a weather strip mountable in a margin between a vehicle door and door frame and structured for guiding excess moisture along the weather strip.

BACKGROUND

It is known to attach weather strips to vehicle doors and/or portions of the vehicle body to which the door is mounted, to prevent moisture and other contaminants from entering the vehicle along margins between door and vehicle body. Portions of the weather strip may be compressible between the door and the vehicle body when the door is completely closed, to provide the requisite contaminant barrier.

A problem may arise with some existing weather strip and/or vehicle door designs, wherein moisture may accumulate on the portion of the weather strip extending along (or parallel to) an uppermost edge of the door. For example, some weather strip designs may have pocket(s) or cavities that accumulate water impinging on the weather strip during a rainstorm when the door is completely closed. Due to the materials from which a weather strip is formed, moisture may also adhere to surfaces of the weather strip. When the door is opened and the weather strip is no longer compressed against the door frame, this trapped moisture may flow along the weather strip, off of the weather strip and into the occupant compartment. This may be exacerbated by vehicle door designs in which the door upper edge and the portion of the weather strip extending along (or parallel to) the door upper edge slope downwardly in a direction extending from the door rear edge toward the door forward edge, when the door is open. This downward slope may cause any moisture on the weather strip to flow into the occupant compartment when the door is opened.

SUMMARY

In one aspect of the embodiments described herein, a weather strip for a vehicle door is provided. The weather strip includes a flow channel extending along at least a portion of the weather strip. A discharge portion is in fluid communication with the flow channel and is structured to enable a liquid to flow therealong from the flow channel to a location outside the flow channel. An end wall extends from a first side of the flow channel and is positioned to direct a liquid impinging on the end wall from the flow channel toward the discharge portion.

In another aspect of the embodiments described herein, a vehicle door is provided. The door has an upper edge and incorporates a weather strip including a portion extending along the door adjacent the door upper edge and including a flow channel structured to guide a liquid flowing along the weather strip. The weather strip also has a discharge portion in fluid communication with the flow channel and through which a liquid flowing from the flow channel is guided away from the flow channel.

DETAILED DESCRIPTION

Embodiments described herein relate to a weather strip for a vehicle door. The weather strip is mountable in a vehicle between the vehicle door and a door frame in which the door is mounted. The weather strip includes a flow channel extending along at least a portion of the weather strip. A discharge portion is in fluid communication with the flow channel and is structured to enable a liquid to flow therealong from the flow channel to a location outside the flow channel. An end wall extends from a first side of the flow channel to prevent liquid from flowing out of the flow channel into an occupant compartment of the vehicle. The end wall may also help guide a liquid impinging on the end wall from the flow channel toward the discharge portion. The weather strip is structured and attached to the door so as to seal the margin between the door and door frame. The flow channel also captures liquid from above the side rail when the door is completely closed. The portion of the weather strip including the flow channel is mounted on the door so as to facilitate a flow of liquid along the flow channel toward the discharge portion. The discharge portion discharges liquid received from the flow channel even when the door is completely closed.

It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures (or similar reference numerals have been provided) to indicate corresponding or analogous elements. Unless otherwise noted, similar reference numerals are used to describe similar features on separate elements and/or embodiments. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details.

FIG.1is a schematic side view of a vehicle19incorporating a side door20including a weather strip (not shown) in accordance with an embodiment described herein.FIG.1shows the side door20in a completely closed condition.FIG.2is a schematic rear view of a portion of the vehicle19ofFIG.1, showing the side door20in an open condition and also showing an exemplary embodiment30of a weather strip in accordance with an embodiment described herein, mounted on surface(s) of the door20structured to face toward an occupant compartment of the vehicle when the door is completely closed. A body19aof the vehicle19may define a door frame19bin which the side door20is mounted.

An embodiment of the weather strip as described herein may be mounted to the side door20so that the weather strip is positioned between the side door20and the vehicle door frame19b(or another portion of the vehicle body) when the door20is completely closed. As is known in the pertinent art, portions of the weather strip may be resiliently compressible between the door20and the door frame19bwhen the door is completely closed, to provide a barrier or seal preventing moisture, dirt, and exhaust fumes from entering the vehicle occupant compartment along the margin between the vehicle door20and the door frame19b. The weather strip may be structured to prevent migration of moisture in both liquid form and vapor form into the occupant compartment.

For purposes of this description, the side door20on which the weather strip is mounted is a rear side door of the vehicle19. However, an embodiment of the weather strip may alternatively be mounted on the front side door21. For the rear side door20, the door frame19bmay be defined at least in part by a “B”-pillar structure19cof the vehicle, a “C”-pillar structure19dof the vehicle, a side rail structure19eand a door lower sill structure19s.

Referring toFIGS.1and2, the vehicle door20may have a forward edge20a(i.e., an edge of the door residing farthest in a forward direction D1of the vehicle19when the door20is mounted on the vehicle19and in a completely closed condition as shown inFIG.1). the door20may be considered “completely closed” or in a “completely closed condition” when the door is in a position where an actuatable latching mechanism (not shown) associated with the door20may be engaged to hold the door20in a closed condition suitable for safely driving the vehicle19along a ground surface.

The door20may also have a rear edge20bpositioned so as to reside opposite the forward edge20a, toward a rearward direction D2of the vehicle19opposite the forward direction D1, when the door20is in the completely closed condition. The door20may also have an upper edge20cconnecting the door forward edge20aand the door rear edge20b, along an uppermost portion of the door20. The door20may also have a lower edge20dconnecting the door forward edge20aand the door rear edge20b, along a lowermost portion of the door20. As shown inFIGS.1and2, portions of the door upper edge20c, forward edge20a, rear edge20ba body20eof the door20may combine to define a frame for a vehicle window20w. The door20may have an inner side20hstructured to face in a direction toward the vehicle occupant compartment when the door20is completely closed.

FIGS.2-7show one exemplary embodiment30of the weather strip mounted on the door20. Some features common to all embodiments of the weather strip will now be described with reference toFIGS.2-7. However, it will be understood that alternative embodiments of the weather strip may differ from weather strip30in other aspects, as described in greater detail herein.

In one or more arrangements, an embodiment of the weather strip mounted on the door20may be formed unitarily as a single piece, using a suitable extrusion or molding process, for example. In other arrangements, the weather strip may be constructed from multiple segments or pieces (not shown) formed separately and structured to be contiguously attachable to associated portions of the vehicle door20to form a continuous barrier. “contiguously attachable” means that each weather strip segment may be connected at each end thereof to another, adjacent segment along the door so as to provide a seal between the door and the vehicle body when the door20is completely closed, to prevent entry of moisture and other contaminants into the vehicle occupant compartment. The term “weather strip” as used herein will refer to a construction formed as a single piece structured to be attachable to the door20as shown inFIG.2to provide a barrier to the passage of contaminants through the weather strip when the door20is completely closed. The term “weather strip” as used herein will also refer collectively to a construction formed from separate segments configurable into an arrangement as shown inFIG.2, to provide a barrier to the passage of contaminants therethrough when the door is completely closed.

Also, unless otherwise shown or described herein, portions of any embodiment of the weather strip may be structured to be attachable to the door20so as to extend along and/or generally parallel to the associated edges of the door20. For example, referring toFIG.2, a first portion32of the weather strip30may be structured to be attachable to the rear side door20so as to extend along and/or generally parallel to the door forward edge20a. A second portion34of the weather strip30may be structured to be attachable to the side door20so as to extend opposite the weather strip first portion32, along and/or generally parallel to the door rear edge20b. A third portion36of the weather strip30may be structured to be attachable to the rear side door20so as to extend between the weather strip first portion32and second portion34and along and/or generally parallel to the door upper edge20c. A fourth portion38of the weather strip30may be structured to be attachable to the rear side door20so as to extend between the weather strip first portion32and second portion34and generally along and/or parallel to the door lower edge20d. Each of weather strip portions32-38may be structured and attached to the door20so as to ensure that the respective weather strip portion will engage an associated portion of the door frame (or another portion of the vehicle body19a) to effect a seal between the weather strip30and the vehicle body as described herein.

Materials of manufacture and/or material surface finishes for the weather strip may include materials to which water has a relatively high adhesion, and also which are suitable for forming a seal or weather-stripping around openings on a vehicle. Possible materials include EPDM rubber, thermoplastic elastomer mixes of rubber and plastic, thermoplastic olefin polymer/filler blends, thermoplastic styrene polymer/filler blends, vinyl chloride resins, and any other suitable material. Portions of any embodiment of the weather strip may be attached to the door20using adhesives, mechanical fasteners, interference fits, and/or any other suitable method or methods.

Each portion of the weather strip30attached to the door20may include an associated sealing portion. Each sealing portion may be compressible between the door20and the door frame/vehicle body when the door is completely closed, to provide an associated barrier or seal as previously described. For example,FIG.3shows a schematic cross-sectional view of the portion36of the weather strip30structured to be attachable to the door20so as to extend along the door upper edge20c, in accordance with an embodiment described herein. The third portion36of the weather strip30includes a sealing portion30s.FIG.3shows the weather strip third portion36attached to the door20with the door completely closed. The sealing portion30sis shown in an undeformed state in phantom lines (occurring when the door is open) and in a resiliently deformed state in solid lines (occurring when the door is completely closed). As seen fromFIG.3, when the door20is completely closed, the sealing portion30smay be resiliently deformed by contact with the side rail structure19eto form a seal therebetween.

Sealing portions similar to sealing portion30smay extend along the lengths of the other weather strip portions32,34,38previously described. Also, similar sealing portions may extend along the entire lengths of the other embodiments130,230,330of the weather strip described herein.

In addition, to enable removal of as much accumulated moisture as possible from the weather strip prior to opening the door, and to help prevent intrusion of liquid from the weather strip into the vehicle occupant compartment when the door is opened, the portion of each weather strip structured to extend along the door upper edge20cmay incorporate a drainage portion connected to the associated sealing portion. For example, the portion36of the weather strip30attached to the door20along door upper edge20cmay include a drainage portion (generally designated36d) connected to associated sealing portion30s.

Each drainage portion of a weather strip may include an associated flow channel extending therealong. for example, referring again toFIG.3, drainage portion36dof weather strip30includes a flow channel36fstructured to extend between the door rear edge20band the door forward edge20awhen the weather strip30is attached to the door20. The flow channel may have a first side36v, a second side36jopposite the first side36v, and a concave portion36yextending between the first and second sides for receiving liquid therein. Similar flow channels may be formed in the associated drainage of the other weather strip embodiments130,230,330described herein.

The flow channel36fmay be structured to collect liquids and suspended contaminants migrating downwardly from the side rail structure19eor otherwise impinging on the weather strip along the margin between the door20and the side rail structure19e. The flow channel36fmay be structured to direct a flow of this liquid along the weather strip third portion36to an associated discharge portion of the drainage portion36p. The flow channel36fmay extend along the entire length (or along substantially the entire length) of the third portion36of the weather strip30.

In addition, in the embodiments described herein, the weather strip may be structured and attached to the door20so as to cause a liquid in the flow channel to flow along the flow channel while the door is completely closed. For example,FIG.4is a schematic view of a side of the door20facing toward the occupant compartment and when the door is completely closed. To urge a liquid in the flow channel36fto flow downwardly when the door20is completely closed, the third portion36of the weather strip30may be structured and attached to the door20along upper edge20cso as to slope downwardly at an angle α with respect to a horizontal plane X2, in a direction extending from the door rear edge20btoward the door forward edge20awhen the door20is completely closed. This helps ensure that the liquid will flow downwardly along the flow channel36ftoward the discharge portion36pas described herein, even when the door20is completely closed, so that liquid may be discharged from the discharge portion36pwhen the door is completely closed.

Also, in one or more arrangements, the door upper edge20cmay be structured so as to slope downwardly in a direction extending from the door rear edge20btoward the door forward edge20a, when the door20is in at least partially open. For example, as seen inFIG.2, the door upper edge20cis shown sloping downwardly at an angle θ with respect to a horizontal plane X1. This slope θ of the door upper edge20cmay be in addition to the slope α of the flow channel when the door20is completely closed. For purposes of determining a downward sloping direction of the door upper edge20c, the door20may be considered to be at least partially open when the door is sufficiently open so that the door rear edge20band the associated portion34of the weather strip30are spaced apart from door frame19b.

In embodiments described herein, the portion of the weather strip structured to extend along the door upper edge20cmay also include a side wall extending from a first side of the flow channel and structured to seal against a portion of the vehicle body when the door is completely closed. As used herein, the terms “seal against” and “sealing against” mean that the side wall is compressible or otherwise deformable responsive to contact with the vehicle body when the door is completely closed, so as to form a seal with the vehicle body preventing liquid from migrating past the side wall/vehicle body contact interface. For example,FIGS.3and4show a side wall36textending from a first side36vof the flow channel36f. Side wall36tis deflected by side rail structure19ewhen the door20is completely closed, causing the side wall36tto seal against the side rail structure19e(or another portion of the vehicle body) when the door20is completely closed.

The side wall36tmay prevent moisture from reaching sealing portion30s, which may be in fluid communication with the occupant compartment. the side wall36tmay also prevent moisture from entering and collecting in a space between the side wall36tand the sealing portion30s, thereby confining the moisture to a side of the side wall36talong which the flow channel36fand drainage portion reside. This facilitates confinement and drainage of all the moisture impinging on the weather strip third portion36. The side wall36tis shown in an undeformed state in phantom lines (occurring when the door is open) and in a resiliently deformed state in solid lines (occurring when the door is completely closed).

Also, as seen inFIG.3, flow channel second side36jmay seal against the side door panel20p(or another portion of the door) to form a seal therebetween when the weather strip30is attached to the door20. The flow channel second side36jis shown in an undeformed state in phantom lines (occurring prior to attachment of the weather strip30to the door20) and in a resiliently deformed state in solid lines (occurring when the weather strip30to the door20). The seals formed by resilient deformation of the flow channel second side36jand the side wall36tmay help ensure that moisture W2flowing off of the side rail structure is directed into the flow channel36f.

The drainage portion of each weather strip described herein may also include an end wall extending from the first side of the flow channel and positioned to direct a liquid impinging on the end wall from the flow channel toward a discharge portion of the drainage portion. Also, as seen in the drawings, the side wall and end wall may intersect each other and may be formed as a single piece with each other in embodiments of the weather strip described herein. for example,FIGS.5-7show an end wall36wextending from a first side36vof the flow channel36fand positioned to direct a liquid impinging on the end wall (in direction D3) from the flow channel36ftoward the discharge portion36p. End wall36wintersects side wall36t. Side wall36tmay also extend past an edge of the end wall36wfor purposes of sealing against a vehicle side rail structure or another portion of the vehicle, as described elsewhere herein.

The end wall36wmay be structured to slow down and bleed momentum from a liquid flowing along the flow channel36fin direction D3toward the vehicle occupant compartment when the door20is opened, while simultaneously directing the liquid toward the discharge portion36p. The end wall36wmay also be structured to prevent a flow of liquid out of the end of the flow channel36fand into the occupant compartment.

Each drainage portion of a weather strip described herein may also include a discharge portion in fluid communication with the flow channel and structured to enable a liquid to flow therealong from the flow channel to a location outside the flow channel. The discharge portion may be located at or near an end of the associated flow channel. For example,FIGS.2,5, and6show a discharge portion (generally designated36p) located at an end of flow channel36f. Referring toFIGS.2,5, and6, the discharge portion36pmay be located generally at or near where the third portion36of the weather strip30intersects the first portion32of the weather strip. The discharge portion36pmay provide a drainage path for moisture off of that portion36of the weather strip30which may otherwise deposit the accumulated liquid into the occupant compartment when the door20is opened.

In one or more arrangements, the weather strip30may be structured to discharge a liquid from the flow channel through a passage36sformed between a side36jof the flow channel and the end wall36w. in one or more particular arrangements, as seen inFIG.7, the discharge portion36pmay be structured to direct at least a portion of the liquid in a direction from the flow channel36ftoward a panel20pof the door. The liquid may then discharge through an opening36qdefined by the end wall36wand the door panel20p.

In one or more arrangements, the discharge portion may have a forward face structured to face in a forward direction of the vehicle19when the door20is completely closed. For example, referring toFIGS.5and7, the discharge portion36pincludes a forward face36zstructured to face in a forward direction of the vehicle19when the door20is completely closed. In one or more arrangements, as seen inFIGS.5and7, the discharge portion36pmay be structured to direct at least a portion of the liquid along the forward face36zof the discharge portion36p, in the direction indicated by arrow W1. Because the momentum of the liquid flowing along the flow channel36fhas been reduced by the end wall36wand because the size of the opening36qdefined by the end wall36wand the door panel20pmay be restricted to limit the flowrate of liquid therethrough, liquid may flow through the opening36qat a speed low enough so that it does not leave the surfaces of the discharge portion36pand enter the occupant compartment. Rather, the liquid exiting through the opening36qmay adhere to the discharge portion36p, flowing down the forward face36z. When the liquid reaches an end of the forward face36z, it may drop vertically off of the forward face36zand away from the discharge portion36pand/or it may continue adhering to the discharge portion36p, flowing onto the first portion32of the weather strip30extending along the door forward edge20aand then further downwardly along this portion of the weather strip.

As described above, all embodiments of the weather strip described herein may include a flow channel, an end wall, and a side wall as described herein. All embodiments of the weather strip may also include an associated discharge portion. However, the structure of the discharge portion may be distinctive to each of the embodiments30,130,230,330of the weather strip described herein.

FIGS.8-10illustrate an alternative embodiment130of the weather strip. The weather strip130may be structured and attached to the door in the same manner as the weather strip30previously described, except that the structure of the discharge portion136pof weather strip130may be different from the structure of discharge portion36p.

Referring toFIGS.8-10, the weather strip130may have a flow channel136f, a side wall136t, an end wall136w, and a discharge portion (generally designated136p). To guide liquid in a direction away from the flow channel136f, discharge portion136pof weather strip130may include a through-hole136hformed along the liquid flow channel136fand structured to enable fluid communication between the flow channel136fand the location outside the flow channel.

As seen inFIGS.8-10, the through-hole136hmay be open or unbounded along one edge or side136sthereof by any portion of the weather strip130. As seen inFIG.10, this open side of the through-hole136hmay be blocked by the door panel20pwhen the weather strip130is attached to the door, thereby closing all sides of the through-hole. In one or more arrangements, the through-hole may be positioned so that a liquid blocked by impinging on the end wall136wpasses through the through-hole136hafter being blocked by the end wall. In one or more particular arrangements, the end wall136wmay be positioned so as to define an edge of the through-hole136h.

In addition, a ramp portion136rmay be structured to extend downwardly from the flow channel136fand the through-hole136hwhen the weather strip130is mounted on a vehicle door as previously described. The ramp portion136rmay be structured to guide a flow of liquid away from the flow channel136f. In particular arrangements, the ramp portion136rmay be structured to guide a flow of liquid downwardly from the flow channel136ftoward a forward face136zof the discharge portion along the direction indicated by arrow W1when the door20is mounted on a vehicle. The liquid may then adhere to (and flow along) the forward face136zas previously described.

FIGS.11-13illustrate another alternative embodiment230of the weather strip. The weather strip230may be structured and attached to the door in the same manner as the weather strips30and130previously described, except that the structure of the discharge portion236pof weather strip230may be different from the structures of discharge portions36pand136p.

Referring toFIGS.11-13, the weather strip230may have a flow channel236f, a side wall236t, an end wall236w, and a discharge portion (generally designated236p). To guide liquid in a direction away from the flow channel236f, discharge portion236pof weather strip230may include a through-hole236hformed along the liquid flow channel236fand structured to enable fluid communication between the flow channel236fand the location outside the flow channel. The through-hole236hmay be structured similarly to the through-hole136hof weather strip130except that, whereas the through-hole136his open along one side or edge thereof as shown inFIGS.8and10, the through-hole236his enclosed or bounded on all sides by other portions of the weather strip230.

In one or more arrangements, the through-hole236hmay be positioned so that a liquid blocked by impinging on the end wall236wpasses through the through-hole236hafter being blocked by the end wall. In one or more particular arrangements, the end wall236wmay be positioned so as to define an edge of the through-hole236h. In addition, a ramp portion236rmay be structured to extend downwardly from the flow channel236fand the through-hole236hwhen the weather strip230is mounted on a vehicle door as previously described. The ramp portion236rmay be structured to guide a flow of liquid away from the flow channel236f. In particular arrangements, the ramp portion236rmay be structured to guide a flow of liquid downwardly from the flow channel236ftoward a forward face236zof the discharge portion along the direction indicated by arrow W1when the door20is mounted on a vehicle. The liquid may then adhere to (and flow along) the forward face236zas previously described.

FIGS.14A-15illustrate yet another alternative embodiment330of the weather strip. The weather strip330may be structured and attached to the door in the same manner as the weather strips30,130, and230previously described, except that the structure of the discharge portion336pof weather strip330may be different from the structures of the other discharge portions36p,136p, and236p.

Referring toFIGS.14A-15, the weather strip330may have a flow channel336f, a side wall336t, an end wall336w, and a discharge portion (generally designated336p). The discharge portion336pmay include a notch or opening336qformed in the end wall336w. Also, the end wall336wand the flow channel336fmay be structured to direct the flow of liquid from the flow channel336fthrough the notch336qto a location outside the flow channel336f. As seen inFIG.15, the weather strip330may be structured so that liquid being discharged through the notch336qflows from the notch downwardly along the forward face336zof the discharge portion336p(or downwardly along another portion of the weather strip330).

In addition, as seen inFIGS.14B and15, the discharge portion336pmay be structured to discharge a flow of liquid from the flow channel336fat a location forward of a forward edge20fof a panel20pof the vehicle door20. Furthermore, as seen inFIGS.14A and14B, the flow channel336fmay be structured to curve in a direction away from the side wall336t(and toward door panel20p) as the flow channel336fextends toward the end wall336w.

In another aspect of the embodiments described herein, a vehicle door may be provided. The door may include an upper edge and an embodiment of a weather strip as described herein. The weather strip may have a portion extending along the door adjacent the upper edge and including a flow channel structured to guide a liquid flowing along the weather strip. The weather strip may also have a discharge portion in fluid communication with the flow channel and through which a liquid flowing from the flow channel is guided away from the flow channel.