Seal assembly for automotive door module

A door assembly may include a sub-assembly having a sub-assembly panel, one or more rails, an edge strip, and a sealing gasket. The rails may extend from the sub-assembly panel and may overhang an edge of the panel to be sealed. The edge strip may be configured to seal the panel extending across a region of the edge where the rail overhangs the edge. The sealing gasket may be a foam-in-place gasket. The sealing gasket may be applied to the sub-assembly panel around the perimeter of the sub-assembly panel and may interact with the edge strip at the region where the at least one rail overhangs the edge to form a contiguous seal around the sub-assembly panel.

BACKGROUND

1. Field of the Invention

The present application generally relates to sealing vehicle assemblies. More specifically, the invention relates to sealing of a component or subassembly within a door assembly for a vehicle door.

2. Description of Related Art

With the increase of electronically automated functionality in vehicles, various electrical assemblies are increasingly installed into vehicle doors. For example a window regulator assembly is provided for supporting and guiding the movement of movable glass in a vehicle side door, generally powered by an electric motor. The window regulator assembly is typically mounted to a door inner panel. Often door inner panel assemblies will be pre-assembled and later attached to the door outer skin. The fully assembled door panels should be sealed to protect the installed assemblies and reduce noise and prevent water and air leakage. A typical operation involves affixing the window regulator assembly being part of a modular assembly with the window regulator guide channels motor and cable guide mountings etc. which is bonded to or affixed to an opening having an edge surrounding the outer perimeter of the assembly. One method of sealing such subassemblies to a door inner panel includes applying a semi liquid sealant or a foam sealant to the panel that acts as a seal against the door inner panel. In some instances, window guide rails may extend beyond the outer perimeter of the window regulator assembly. These rails may over hang regions of the edge of the panel. In the case of applying a foam sealant bead, applying foam underneath these overhanging regions may be challenging because ideally the nozzle dispensing the foam would be perpendicular to the surface of the panel where the overhanging portion interferes with such access.

In view of the above, it is apparent that there exists a need for an improved assembly and method for sealing components or subassemblies to door assemblies.

SUMMARY

In satisfying the above need, as well as overcoming the enumerated drawbacks and other limitations of the related art, the present disclosure provides an improved assembly and method for sealing components or subassemblies of door assemblies.

A typical door assembly may include a door outer panel, an inner panel, and a window regulator assembly having one or more guide rails, an edge strip, and a sealing gasket. The rails may extend from the sub-assembly panel and may overhang an edge of the panel to be sealed. The edge strip may be configured to seal the panel extending across a region of the edge where the rail overhangs the edge. The sealing gasket may be a foam-in-place gasket. The sealing gasket may be applied to the sub-assembly panel around the perimeter of the sub-assembly panel and may interact with the edge strip at the region where the at least one rail overhangs the edge to form a contiguous seal around the sub-assembly panel. The edge strip may have a sealing portion or a foam-in-place gasket that contact and form a seal with sealing gasket applied to the sub-assembly panel. The edge strip may overlap the sealing gasket in one or more directions to improve the sealing between the gasket and regions of the panel.

DETAILED DESCRIPTION

FIG. 1is a schematic view of a vehicle door assembly100. The vehicle door assembly100includes door outer panel110, a door inner panel111, and sub-assembly120(e.g. a window regulator assembly). The sub-assembly120may include a sub-assembly panel112and glass slide rails116. The window regulator electronics and slide rails may be provided as a sub-assembly mounted to the panel112. The panel112may also include cable channels and cable pulley mounts for the cable system which guides the side door glass between open and closed positions as the glass panel (not shown) slides along the slide rails. The window regular assembly and slide rails may provided as a single window regulator subassembly. The subassembly panel112may have an outer perimeter edge which forms a seal against the perimeter edge of the door inner panel aperture122when the components are assembled. It may be important that when sub-assembly120is mounted position, a weathertight seal114is provided at the interface around the perimeter edges of the sub-assembly panel112and the inner door panel111. In certain embodiments, the rails116may overhang the edge of the window regulator subassembly. The seal114may form a continuous seal of the sub-assembly against the inner door panel111to prevent the passage of moisture through the aperture in the door assembly100. The perimeter of the sub-assembly panel112where the seal114will be applied may be plasma treated to improve adhesion characteristics of the panel112to the seal114.

The seal114may be provided through a foam-in-place gasket that is applied around the perimeter edge of the sub-assembly panel112. The rails116may overhang the edge of the sub-assembly panel112. The position of the rails116may cause difficulties when placing the seal114in the form of a liquid applied dispensed material around the perimeter where the rails overhang the edge of the sub-assembly panel. Ideally, when applying a foam-in-place gasket the nozzle applying the gasket would be oriented perpendicular to the surface to which the foam-in-place gasket is applied. However, the overhanging region of the rails may make optimal positioning of the nozzle difficult or impossible.

FIG. 2is an illustration of one method for applying a seal to the sub-assembly. The sub-assembly panel212may have rails216extending from the sub-assembly panel212and overhanging an edge of the sub-assembly panel212. As previously discussed, the region where the rails216overhang the sub-assembly panel212may be a difficult area in which to apply a foam-in-place gasket. Accordingly, separately manufactured edge strip218may be applied to the edge in the region where the rails216overhang the edge. As such, the edge strip218may provide sealing in the overhanging region. For example the edge strip218may be formed of a solid EPDM (Ethylene Propylene Diene Monomers) or TPV (Thermoplastic Vulcanizates) material. The edge strip218may be extruded and, therefore, may have a uniform cross-sectional profile that is configured to mate over the edge of the sub-assembly panel212. The edge strip218may be installed onto the panel assembly by hand or may be machine installed.

A region around the perimeter of the of the sub-assembly panel212where the sealing material214will be placed may be plasma treated to improve adhesion characteristics of the sub-assembly panel212to the sealing material214. Once the edge strip is placed over the edge in the overhanging region, a sealing material214may be placed around the perimeter of the sub-assembly panel212. The sealing material214may be a foam-in-place gasket. The sealing material214may abut or overlap with the edge strip218to form a contiguous seal around the perimeter of the edge panel212. In various alternative implementations, the sealing material214may be applied before or after installation of the edge strip218.

In order to provide a continuous seal around the perimeter of edge it may be desirable that an interface between the sealing material214and the edge strip218be provided. The interface may be a chemical bonding between the sealing material214and a portion (e.g. a sealing portion) of the edge strip218.FIG. 3Aillustrates a end of the sealing portion of the edge strip218abutting an end of the sealing material214. The ends may form a chemical bond with one another.FIG. 3Billustrates a side of the sealing portion of the edge strip218overlapping250longitudinally with a side of the sealing material214. The side of the sealing portion may chemically bond with the side of the sealing material214.FIG. 3Cillustrates the sealing portion of the edge strip218extending over the sealing material214. As such, the sealing material214may be sandwiched between the edge strip218and the sub-assembly panel212. The region where the edge strip218extends over the sealing material214forms an overlap region260. Although, it is also contemplated that the sealing material214could be applied over the edge strip218, sandwiching the edge strip218between the sealing material214and the sub-assembly panel210.

FIG. 4Ais a sectional side view of one implementation of the panel assembly.FIG. 4Bis a perspective view of the panel assembly inFIG. 4A. The panel assembly includes a sub-assembly panel310, an edge strip312, and a seal330. The sub-assembly panel310may be a plastic module or plate. The sub-assembly panel may be formed to be installed within a hole on the inner panel of an inner door panel. The seal330prevents moisture from traveling through the hole between the inner door panel and the sub-assembly, as well as, reducing noise.

The sub-assembly panel310may include rails that overhang an edge318of the sub-assembly panel310. The edge strip312may be placed over the edge318in the region where the rails overhang the sub-assembly panel. The edge strip312may be formed from an EPDM or TPV (Thermoplastic Vulcanizates) material. Further, the edge strip may be an extruded part and, therefore, may have a uniform cross-sectional profile along the length of the edge strip.

The edge strip312may be formed of a high durometer material, for example, the edge strip may have a durometer value of 80-90 Shore A scale. The edge strip312may be formed of a solid rubbery material which is flexible enough to follow the curvature on the plate and strong enough to fasten to the plate with retaining feature. The edge strip312may be fitted over the edge318of the panel310and extend downward along both sides of the panel310. The portions extending downward along the side of the panel310may include locking features322that engage with locking features320of the sub-assembly panel310. Accordingly, the edge strip312may be locked into place over the edge318of the sub-assembly panel310. One of the sides of the edge strip may extend along the side of the sub-assembly panel310and may form a channel314within the edge strip312.

A foam-in-place gasket316may be applied within the channel314. The foam-in-place gasket316may be applied to the edge strip312prior to fitting the edge strip312on the edge318of the sub-assembly panel310. A plasma treatment or primer may be applied to the channel314prior to the application of the foam-in-place gasket316to improve adhesion between the surface of the channel314and the foam-in-place gasket316.

The sub-assembly panel310may also have a channel332configured to receive a foam-in-place gasket around the perimeter of the rest of the sub-assembly panel that is not in the region where the rails are overhanging the edge of the sub-assembly panel. As such, a foam-in-place gasket330may be applied within the channel332around the perimeter of the sub-assembly panel310. A plasma treatment or primer may be applied to the channel332prior to the application of the foam-in-place gasket330to improve adhesion between the surface of the channel332and the foam-in-place gasket330.

The foam-in-place gasket316and the foam-in-place gasket330may contact each other to form a contiguous seal around the perimeter of the panel. In some implementations, the side of the foam-in-place gasket316may overlap with the side of the foam-in-place gasket330to provide an improved sealing between regions of the sub-assembly panel310and the edge strip312.

FIG. 5Ais a sectional side view of another implementation of the panel assembly.FIG. 5Bis a front view of the panel assembly inFIG. 5A. The panel assembly includes a sub-assembly panel410, an edge strip412, and a seal430. The sub-assembly panel410may be a plastic module or plate. The sub-assembly panel may be formed to be installed within a hole on the inner panel of a door assembly. The seal430prevents moisture (water, air) from traveling through the hole between the door assembly and the panel assembly, as well as, reducing noise.

The sub-assembly panel410may include rails that overhang an edge418of the sub-assembly panel410. The edge strip412may be placed over the edge418in the region where the rails overhang the sub-assembly panel. The edge strip412may be formed from an EPDM (Ethylene Propylene Diene Monomers) or TPV (Thermoplastic Vulcanizates) material. Further, the edge strip may be an extruded part and, therefore, may have a uniform cross-sectional profile along the length of the edge strip.

The edge strip412may be formed of a high durometer material, for example, the edge strip may have a durometer reading of 80-90. The edge strip412may be fitted over the edge418of the panel410and extend downward along both sides of the panel410. The portions extending downward along the side of the panel410may include locking features422that engage with locking features420of the sub-assembly panel410. The locking features may be provided on one or both sides of the sub-assembly panel410. Accordingly, the edge strip412may be locked into place over the edge418of the sub-assembly panel410. One of the sides of the edge strip may extend along the side of the sub-assembly panel410and include a sealing portion416. The sealing portion416may be formed of an EPDM or TPV (Thermoplastic Vulcanizates) sponge material. In one example, the EPDM or TPV closed cell sponge material may have a density of about 0.2-0.5 g/cm3. Although, it is understood that other elastic materials may be used for the sealing portion416. The sponge material may be bonded to a solid rubber portion of the of the edge strip412that extends over the edge418and engages the panel410. However, the sealing portion416may be attached to an attachment surface414of the edge strip412using various methods including molding, adhesive, etc.

While the engaging portion of the edge strip412may be formed of a higher density material than the sealing portion416, the engaging portion of the edge strip412may also be formed of the same material as the sealing portion416or a material similar to the density of the sealing portion416. The edge strip412may be snapped over the edge418or slid onto the edge418from the side of the panel410. Further, the edge strip may be extruded or molded or over-molded onto the panel410and may have a top edge that is straight or forms a transitional curve. While the sealing portion416is shown a solid, the sealing portion416may be hollow, for example as shown inFIG. 7.

The sub-assembly panel410may have a channel432configured to receive a foam-in-place gasket around the perimeter of the rest of the sub-assembly panel that is not in the region where the rails are overhanging the edge of the sub-assembly panel. As such, a foam-in-place gasket430may be applied within the channel432around the perimeter of the sub-assembly panel410. A plasma treatment or primer may be applied to the channel432prior to the application of the foam-in-place gasket430to improve adhesion between the surface of the channel432and the foam-in-place gasket430.

The sealing portion416and the foam-in-place gasket430may contact each other to form a contiguous seal around the perimeter of the panel. The side of the sealing portion416may overlap with the side of the foam-in-place gasket430to provide an improved sealing between regions of the sub-assembly panel410and the edge strip412. The sealing portion416of edge strip412may overlap the foam-in-place gasket430in a direction parallel with the edge (with a plane parallel to the edge designated inFIG. 5Aas Parallel). In some implementations, the sealing portion416of edge strip412may overlap the foam-in-place gasket430in a direction perpendicular with the edge and the panel410(with a plane perpendicular to the edge designated inFIG. 5Aas Perpendicular) to form a vertical overlap region440. In some implementations, the sealing portion416of edge strip412may form a horizontal overlap region443with a longitudinal side of the foam-in-place gasket430. Further, the locking features may force the sealing portion416of the edge strip412against the foam-in-place gasket430.

FIG. 6Ais a sectional side view of another implementation of the panel assembly.FIG. 6Bis a perspective view of the panel assembly inFIG. 6A. The panel assembly includes a sub-assembly panel510, an edge strip512, and a seal530. The sub-assembly panel510may be a plastic module or plate. The sub-assembly panel may be formed to be installed within a hole on the inner panel of a door assembly. The seal530prevents moisture from traveling through the hole between the door assembly and the panel assembly, as well as, reducing noise.

The sub-assembly panel510may include rails that overhang an edge518of the sub-assembly panel510. The edge strip512may be placed over the edge518in the region where the rails overhang the sub-assembly panel. The edge strip512may be formed from an EPDM (Ethylene Propylene Diene Monomers) or TPV (Thermoplastic Vulcanizates) material. Further, the edge strip may be an extruded part and, therefore, may have a uniform cross-sectional profile along the length of the edge strip.

The edge strip512may be formed of a high durometer material, for example, the edge strip may have a durometer reading of 80-90. The edge strip512may be fitted over the edge518of the panel510and extend downward along both sides of the panel510. The portions extending downward along the side of the panel510may include locking features522that engage with locking features520of the sub-assembly panel510. The locking features may be provided on one or both sides of the sub-assembly panel510. Accordingly, the edge strip512may be locked into place over the edge518of the sub-assembly panel510.

One of the sides of the edge strip may extend along the side of the sub-assembly panel510and include a sealing portion516. The sealing portion516may be formed of an EPDM or TPV closed cell sponge material. The EPDM or TPV closed cell sponge material may have a density of about 0.2-0.5 g/cm3. In one example, the sponge material may be bonded to an EPDM or TPV solid rubber portion of the of the edge strip512that extends over the edge518and engages the panel510. Although, it is understood that other elastic materials may be used for the sealing portion516. However, the sealing portion516may be attached to an attachment surface514of the edge strip512using various methods described throughout this application. The edge strip512may be extruded to match to an angle of the edge518of the panel510and for example present the sealing portion516parallel to a front surface of the panel and the foam-in-place seal530. The locking features may force the sealing portion516of the edge strip512against the foam-in-place gasket530.

While the engaging portion of the edge strip512may be formed of a higher density material than the sealing portion516, the engaging portion of the edge strip512may also be formed of the same material as the sealing portion516or a material similar to the density of the sealing portion516. The edge strip512may be snapped over the edge518or slid onto the edge518from the side of the panel510. Further, the edge strip may be extruded or molded or over-molded onto the panel510and may have a top edge that is straight or forms a transitional curve. While the sealing portion516is shown a solid, the sealing portion516may be hollow, for example as shown inFIG. 7.

The sub-assembly panel510may have a channel532configured to receive a foam-in-place gasket around the perimeter of the rest of the sub-assembly panel that is not in the region where the rails are overhanging the edge of the sub-assembly panel. As such, a foam-in-place gasket530may be applied within the channel532around the perimeter of the sub-assembly panel510. A plasma or primer treatment may be applied to the channel532prior to the application of the foam-in-place gasket530to improve adhesion between the surface of the channel532and the foam-in-place gasket530.

The sealing portion516and the foam-in-place gasket530may contact each other to form a contiguous seal around the perimeter of the panel. The side of the sealing portion516may overlap with the side of the foam-in-place gasket530to provide an improved sealing between regions of the sub-assembly panel510and the edge strip512. The sealing portion516of edge strip512may overlap the foam-in-place gasket530in a direction parallel with the edge. In some implementations, the sealing portion516of edge strip512may be flat and abut the foam-in-place gasket530in a direction perpendicular with the edge and substantially in plane with the panel510. In some implementations, the sealing portion516of edge strip512may form a horizontal overlap region with a longitudinal side of the foam-in-place gasket530.

FIG. 7Ais a sectional side view of another implementation of the panel assembly.FIG. 7Bis a perspective view of the panel assembly inFIG. 7A. The panel assembly includes a sub-assembly panel610, an edge strip612, and a seal630. The sub-assembly panel610may be a plastic module or plate. The sub-assembly panel may be formed to be installed within a hole on the inner panel of a door assembly. The seal630prevents moisture (water and air) from traveling through the hole between the door assembly and the panel assembly, as well as, reducing noise.

The sub-assembly panel610may include rails that overhang an edge618of the sub-assembly panel610. The edge strip612may be placed over the edge618in the region where the rails overhang the sub-assembly panel. The edge strip612may be formed from an EPDM (Ethylene Propylene Diene Monomers) or TPV (Thermoplastic Vulcanizates) material. Further, the edge strip may be an extruded part and, therefore, may have a uniform cross-sectional profile along the length of the edge strip.

The edge strip612may be formed of a high durometer material, for example, the edge strip may have a durometer reading of 80-90. The edge strip612may be fitted over the edge618of the panel610and extend downward along both sides of the panel610. The portions extending downward along the side of the panel610may include locking features that engage with locking features of the sub-assembly panel610. The locking features may be provided on one or both sides of the sub-assembly panel610. Accordingly, the edge strip612may be locked into place over the edge618of the sub-assembly panel610.

One of the sides of the edge strip may extend along the side of the sub-assembly panel610and include a sealing portion616. The sealing portion616may be formed of an EPDM or TPV closed cell sponge material. The EPDM or TPV closed cell sponge material may have a density of about 0.2-0.5 g/cm3. In one example, the sponge material may be bonded to an EPDM or TPV solid rubber portion of the of the edge strip612that extends over the edge618and engages the panel610. Although, it is understood that other elastic materials may be used for the sealing portion616. However, the sealing portion616may be attached to an attachment surface614of the edge strip612using various methods described throughout this application. The sealing portion616may form a hollow tube such as a bubble. One end of outer wall of the tube may be bonded to and extend away from the attachment surface614. The other end of the outer wall of the tube may loop around forming a hollow passageway and be bonded to another portion of the attachment surface614.

The edge strip612may be extruded to match to an angle of the edge618of the panel610and for example present the sealing portion616parallel to a front surface of the panel and the foam-in-place seal630. The locking features may force the sealing portion616of the edge strip612against the foam-in-place gasket630.

While the engaging portion of the edge strip612may be formed of a higher density material than the sealing portion616, the engaging portion of the edge strip612may also be formed of the same material as the sealing portion616or a material similar to the density of the sealing portion616. The edge strip612may be snapped over the edge618or slid onto the edge618from the side of the panel610. Further, the edge strip may be extruded or molded or over-molded onto the panel610and may have a top edge that is straight or forms a transitional curve. While the sealing portion616is shown a solid, the sealing portion616may be solid, for example as shown inFIG. 5andFIG. 6.

The sub-assembly panel610may have a channel632configured to receive a foam-in-place gasket around the perimeter of the rest of the sub-assembly panel that is not in the region where the rails are overhanging the edge of the sub-assembly panel. As such, a foam-in-place gasket630may be applied within the channel632around the perimeter of the sub-assembly panel610. A plasma treatment or primer may be applied to the channel632prior to the application of the foam-in-place gasket630to improve adhesion between the surface of the channel632and the foam-in-place gasket630.

The sealing portion616and the foam-in-place gasket630may contact each other to form a contiguous seal around the perimeter of the panel. The side of the sealing portion616may overlap with the side of the foam-in-place gasket630to provide an improved sealing between regions of the sub-assembly panel610and the edge strip612. The sealing portion616of edge strip612may overlap the foam-in-place gasket630in a direction parallel with the edge. In some implementations, the sealing portion616of edge strip612may be flat and abut the foam-in-place gasket630in a direction perpendicular with the edge and substantially in plane with the panel610. In some implementations, the sealing portion616of edge strip612may form a horizontal overlap region with a longitudinal side of the foam-in-place gasket630.

Various feature described in each of these implementations may be used in combination together. For example, the foam-in-place gasket applied to the edge strip may form any of the overlap regions described with respect to the other figures. As such, the disclosure provides new an novel features that address specific technical manufacturing problems.

As a person skilled in the art will readily appreciate, the above description is meant as an illustration of the principles of this disclosure. This description is not intended to limit the scope or application of this disclosure in that the invention is susceptible to modification, variation and change, without departing from spirit of this disclosure, as defined in the following claims.