Window molding members and method of manufacturing same

Abstract: The disclosure relates to a molding member (4), for instance for automobile front window plates (2), formed at least partly of an extruded body of a synthetic resin material, as well as a method of manufacturing such molding members (4). The molding member (4) has an integral lip section (4b) in the form of a ridge which extends throughout the entire length, as well as a core element (22) embedded in the main body (4a) to extend into the lip section (4b). Typically, the lip section (4b) bears against the outer surface of the window plate (2) along the upper portion to realize a flush outer surface along junctions between the upper edge of the window plate (2) and the body panel (7), but is spaced therefrom along the side portions (6)to define a weir (8). The weir (8) is formed by plastically deforming a predetermined location of the core element (22), and prevents flow of the rain water across the molding member (4) to preserve the driver's or navigators' sight through a window (2).

Description: The present invention relates to a window molding member, for instance for automobiles, as well as a method of manufacturing such molding members. An automobile employs various kinds of molding members, of which a typical example is a window molding member adapted to extend along the periphery of front or rear window plate, i.e. along a pair of front or rear pillars and the front or rear edge of the roof panel of the automobile body. A variety of requirements are imposed on molding members mainly from design and/or functional viewpoint, and resulted in an increased demand in the automobile industry for the molding members whose cross-sectional shape varies in the longitudinal direction. Specifically, one proposal is disclosed for example in Japanese Utility Model Examined Publication No. 57-54,416, which is directed to a window moulding member having an upper portion with a first predetermined cross-section, and a side portion with a second predetermined cross-section which is different from the first cross-section, wherein the upper and side portions are prepared separately from each other. When such moulding member is arranged along the periphery of a front window plate, the second cross-section of the side portion serves to define a weir solely along the side edge of the window plate. Thus, during driving in a rainy condition, the weir prevents rain water from flowing across the moulding member toward an adjacent side window, thereby effectively preserving driver's and/or navigator's sight therethrough. To produce a window moulding member with a cross-section which varies in the longitudinal direction, it is possible to physically divide each moulding member into first and second extruded portions with the respectively predetermined cross-sectional shapes, which are connected with each other either by an injection moulding process or by using a separate corner connection piece. However, connection of these two portions by means of the injection moulding accompanies formation of undesirable burrs along the junctions and deterioration in the appearance, while use of the corner connection piece results in an increased number of the required components and assembly steps. Another possibility for manufacturing moulding members with a longitudinally variable cross-section is disclosed in Japanese Patent Application Laid-open No. 62-231,814, wherein the main body of the molding member has a lip section in the form of a ridge, and two leg sections both to be inserted into a gap between the automobile body panel and the window plate. In use, the first leg section along the upper and side portions of the molding member is engaged by a retainer member on the automobile body panel such that the molding member is retained in position. Furthermore, the second leg section is directly engaged with the periphery of the window plate along the upper portion whereby the lip section is brought into direct contact with the surface of the window plate along the upper portion, while a separate erection member accommodating the second leg section therein is engaged with the periphery of the window plate along the side portion such that the second leg section is supported by the erection member and urges and deforms the lip section away from the surface of the window plate along the side portion to form the weir between the window plate and the ridge. Such an arrangement provides refined appearance due to the continuous and smooth surface along the corner portions integrally connecting the upper and side portions with each other. However, use of the erection members along the both side portions is sometimes problematic in that, besides an increased number of required components and assembly steps, the lip section tends to be deformed when applied with external force, and it is difficult to stably maintained the desired cross-section of the weir for a long period. Therefore, it is a primary aim of the present invention to provide a novel window molding member with a longitudinally variable cross-section, which can be readily realized in a facilitated manner and with an improved productivity, in which the deformation of the lip section can be effectively suppressed even when it is applied with external force, and in which the desired shape of the bank or channel or weir (hereinafter referred to as "weir") can be stably maintained for a long period. Another aim of the present invention is to provide a novel method by which window molding members with a longitudinally variable cross-section can be produced in a facilitated manner and with an improved productivity, and which makes it possible to effectively suppress the deformation of the lip section even when it is applied with external force, and to maintain the desired cross-section of the weirs in a stable manner and for a long period. According to one aspect of the present invention, there is provided a window moulding member, for instance for automobiles, comprising: a main body comprising a continuous elongate member including an upper portion to extend along an upper edge of a window plate, at least one side portion to extend along a side edge of said window plate and at least one corner portion integrally joining said upper and side portions, said main body having a longitudinal shape corresponding to the edge of said window plate; a lip section extending along the length of the main body and integral therewith; a core element integrally provided with the main body and extending into the lip section; said core element having been deformed plastically, at least locally in the longitudinal direction of the core element, such that said moulding member has different cross-sections in said upper and side portions and gradually changes cross-section substantially through said corner portion to define, when said moulding member is mounted in place, at least one weir along either said upper or side portion to guide rain water along the weir and prevent it from flowing across the moulding member. According to another aspect of the present invention, there is provided a method of manufacturing window mouldings, for instance for automobiles, comprising the steps of: forming a main body composed at least partly of a continuous elongate material, including an upper portion to extend along an upper edge of a window plate, at least one side portion to extend along a side edge of the window plate, and at least one corner portion connecting said upper portion and said side portion with each other, the main body further including an integral lip section formed to extend over the entire length thereof, and a core element integrally provided with the main body and extending into said lip section; axially bending said main body into a shape corresponding longitudinally to the contour of said window plate; and plastically deforming said core element, at least locally in the longitudinal direction of the core element, so that the moulding member has different cross-sections in the upper and side sections and gradually changes cross-section substantially through the corner section to define at least one weir, when the moulding member is mounted in place, along either said upper portion or said side portion to guide rain water along the weir and prevent it from flowing across the moulding member. In accordance with the present invention, the longitudinally variable cross-section of the molding member can be readily realized, simply by plastically deforming the core element such that the lip section defines at least one weir along the side portion of the molding member when it is for a front window plate, or defines a weir along the upper portion of the molding member when it is for a rear window plate. The desired cross-section of the weir can be obtained by the plastically deformed core element, without separately prepared erection members to form the weirs, so that the present invention makes it possible, not only to highly improve the productivity and to preserve an excellent appearance of the product, but also to suppress undesirable deformation of the lip section even when it is applied with external force, and to maintain the desired cross-section of the weirs in a stable manner and for a long period. For a better understanding of the invention, reference is taken to the accompanying drawings, in which: Fig. 1 is a perspective view of an automobile with window molding members to which the present invention may be applied; Fig. 2 is a cross-sectional view, taken along the line A-A in Fig. 1, of the side portion of a front window molding member according to one embodiment of the present invention; Fig. 3 is a cross-sectional view, taken along the line B-B in Fig. 1, of the upper portion of the window molding member of Fig. 2; Fig. 4 is a fragmentary view, as seen in the direction of arrow C in Fig. 1, of the window molding member of Fig. 2; Fig. 5 is a cross sectional view, similar to Fig. 2, of the front window molding member according to another embodiment of the present invention; Fig. 6 is a system diagram of one example of the production line which is adapted to carry out the method of the present invention for producing the window molding members; Fig. 7 is a plan view of an axial bending and shaping device to be used in conjunction with the production line of Fig. 6; Fig. 8 is a fragmentary perspective view of the window molding member to be subjected to axial bending and shaping by the device of Fig. 7; and Fig. 9 is a sectional view taken along the line D-D in Fig. 7. The present invention will now be explained in further detail, by referring to some preferred embodiments shown in the attached drawings. There is shown in Fig. 1 an automobile which is designated as a whole by reference numeral 1, and which includes a front window plate 2 and side window plates 3. The front window plate 2 may be composed of a transparent inorganic glass or transparent synthetic resin, such as polycarbonate resin, acrylic resin or the like, and is secured to the automobile body panel 7 by means of an adhesive material 9, with a rubber dam member 10 arranged between the window plate 2 and a depressed seat portion 7b of the panel 7. The window plate 2 may be provided on its rear surface with an opaque printed layer 20 which extends along the periphery of the plate 2 such that the adhesive material 9 and the dam member 10 are not visible from outside, to realize a refined appearance. The front window plate 2 is associated with an elongate window molding member 4 which is arranged to cover a gap or space S between the automobile body panel 7 and the peripheral edge of the front window plate 2, as particularly shown in Figs. 2 and 3. The molding member 4 has a pair of side portions 6 (Fig. 2) along the side edges of the window plate 2, an upper portion 5 (Fig. 3) along the upper edge of the window plate 2, and a pair of corner portions 11 where the cross-section of the side portions 6 gradually changes to that of the upper portion 5. The molding member 4 has a main body 4a composed of a flexible and/or soft polyvinylchloride (PVC) resin, ionomer resin, ethylenevinyl acetate copolymer (EVA) resin, transparent cellulose acetate butylate (CAB) resin, appropriate synthetic rubber material or other suitable thermoplastic and elastomeric synthetic resin material with a flexibility. The material forming the main body 4a is co-extruded with a core element 22 with an ornamental portion 23, into an elongate member with a substantially constant cross-section. The core element 22 is substantially completely embedded into the material of the main body 4a, with the exception that the ornamental portion 23 having an outer surface with a metallic luster or desired color is exposed outside. The main body 4a includes a leg section 13 to be inserted into the space S between the automobile body panel 7 and the edge of the front window plate 2, as well as a pair of lip sections 4b, 4c formed on the top of the leg section 13 to project from both sides thereof. These lip sections are each in the form of a ridge which extends along the entire length of the extruded elongate member. The lip section 4c has a free end bearing against the outer surface of the automobile body panel 7 in the upper and side portions 5, 6 of the molding member 4 (Figs. 2 and 3). On the other hand, the lip section 4b has a free end which bears against the outer surface of the window plate 2 in the upper portion 5 (Fig. 3), but which is spaced therefrom along the side portions 6 of the molding member 4 so as to define a weir 8. The leg section 13 of the main body 4a has at least one fin 15 formed on that side which is remote from the window plate 2. The fin 15 is engageable with an elongate strip-like retainer 17 which is secured to a shoulder portion 7a of the body panel 7 adjacent to the depressed seat portion 7b. The leg section 13 has a free end in the form of a projection 16a which is engageable with the rear edge of the window plate 2, as well as an additional projection 16b which, in turn, is engageable with the front edge of the window plate 2. The core element 22 embedded in the main body 4a is composed of a metal sheet with a sufficient strength to reinforce the material of the main body 4a, and may thus be composed of stainless steel sheet, aluminum sheet, galvanized steel sheet, or the like. Furthermore, when the core element 22 is composed of a galvanized steel sheet, it is advantageous to form the ornamental portion 23 by adhering a lustrous metal foil or sheet, colored resin sheet, or the like, and to embed all the remaining portions into the material of the main body 4a. The core element 22 has such a profiled cross-section with one or more folded portions 24, that it is present in the projection 16b, and also extends into the ridge 4b. The window molding member 4 of such arrangement includes integrally connected upper and side portions 5, 6, and a lip section 4b in the form of a ridge which has been subjected to such a plastic or non-elastic deformation that its cross-section along the upper portion 5 differs from that along the side portions 6. Fig. 5 is a cross-sectional view, also taken along the line A-A in Fig. 1, showing another embodiment of the window molding member wherein the core element 22 is not exposed outside, and a transparent resin layer 25 is formed on the outer surface of the ornamental portion 23 of the core element 22 such that the ornamental portion 23 is visible from outside. The transparent resin layer 25 may be replaced by appropriately colored opaque resin layer, to form an ornamental portion separately from the core element 22, if desired. The window molding member of the above mentioned embodiments can be advantageously produced by the method according to the present invention, with a production line to be fully described hereinafter. There is shown in Fig. 6 a system diagram of the production line which includes a first uncoiler 31 for continuously supplying a metal sheet or the like strip material 32 to a roll forming machine 33, where it is shaped into the desired cross-sectional profile of the core element 22, which is then supplied to an extrusion die 34 and co-extruded with a thermoplastic resin, such as a PVC resin into a continuous rod 35 of the configuration as shown in Fig. 8, having a cross-section corresponding to that shown in Fig. 2. The so-formed continuous rod 35 is fed to a sizing/cooling station 36 which includes a sizing device 36a and a cooling tank 36b. At this station 36, the continuous rod 35 is subjected to a required sizing and also to a simultaneous cooling in a cooing tank 36b. The continuous rod 35 is then covered by a protective tape 39 supplied from an uncoiler 38, is hauled by an appropriate hauling device 40, and is further fed to a cutting station 41 where it is successively cut into an elongate member 35B with a predetermined length. The so-obtained elongate member 35B with the predetermined length, obtained as above, is generally straight in its longitudinal direction, and has a constant cross-section along the entire length, corresponding to the cross-section of the molding member 4 in its side portion 6 (Fig. 2). Consequently, it is necessary to axially bend the elongate member 35B into conformity with the contour of the window plate 2, and also to plastically deform the lip section 4b and the core element 22 locally in the longitudinal direction to realize the cross-section of the molding member 4 in its upper portion 5 (Fig. 3). It is from this reason that the above-mentioned production line is followed by an axial bending and shaping device 42 to be described hereinafter. The shaping device 42 includes, as particularly shown in Figs. 7 and 9, a central die plate 43, and upper and lower die plates 44, 45 on both sides thereof. These die plates 43, 44, 45 are superimposed upon, and united with each other to form an integral abutment die assembly having in its outer periphery a shaping groove 46, which is adapted to receive the elongate member 35B. The central die plate 43 has an outer contour which substantially corresponds to that of the window plate 2, and is adapted to support the lip section 4b and the projection 16b of the leg section 13. The upper die plate 44 cooperates with the central die plate 43 such that the lip section 4b is urged against that portion of the central die plate 43 which corresponds to the upper portion 5, as shown in Fig. 9, and is kept spaced from those portions of the central die plate 43 which correspond to the side and the corner portions 6, 11. On the other hand, the lower die plate 45 is to support the projection 16a of the leg section 13. The shaping device 42 further includes a pair of chucks 47, only one of which is shown in Fig. 7, for clamping both ends of the elongate member 35B. The elongate member 35B is subjected to an axial bending and also to a local plastic deformation of the lip section 4b in the following manner. First of all, as shown in Fig. 7, the elongate material 35B is clamped on its both ends by chucks 47, and is aligned with and urged against the shaping groove 46 while being applied with a tension in the direction X. Thereafter, the chucks 46 are moved in the direction Y, and the core element 22 of the elongate member 35B is subjected to a required plastic deformation, to induce the plastic deformation of the lip section 4b simultaneously with the axial bending such that it can be brought into contact with the window plate 2 along the upper portion 5. In this case, when the core element 22 is plastically deformed around the folded portion 24, it is possible to deform the lip section 4b without subjecting the remaining portions to an excessive deformation. Finally, the ends of the elongate member 35B are disengaged from the chucks 47 and cut away to form a finished molding member 4. The window molding member 4 produced as above is mounted in place in the following manner. First of all, the elongate retainer member 17 is previously adhered to the entire periphery, except the lower portion, of the shoulder portion 7a of the automobile body panel 7 which has already been subjected to painting and baking. While the rear surface of the outer periphery of the window plate 2, which has already been formed with an opaque printed layer 20, is further provided with a dam rubber 10, and the entire periphery on the rear surface of the window plate 2, including the lower portion, is applied with a liquid adhesive material 9 after projections 16a, 16b of the window molding member 4 have been engaged with the periphery of the window plate 2. This assembly is then fitted into the shoulder portion 7a of the automobile body panel 7, and is firmly secured after the hardening of the adhesive material 9, with the retaining fins 15 in engagement with the retainer member 17. The window molding member 4 mounted in place covers the space S between the window plate 2 and the automobile body panel 7. The free end of the lip section 4b along the upper portion 5 of the molding member 4 is in contact with the outer surface of the widow plate 2, as shown in Fig. 3, and contributes to realize smooth or so-called flush outer surface of the automobile body. The free end of the lip section 4b along the side portions 6 of the molding member 4 is spaced from the outer surface of the window plate 2, as shown in Fig. 2, and cooperates with the window plate 2 to form the weirs 8 therebetween. Thus, during the driving in a rainy condition, the rain water 21 on the window plate 2 is collected into, and guided by the weirs 8 along the side portions 6, and can be prevented from flowing onto the side windows 3. Despite absence of the weir 8 along the upper portion 5, the above-mentioned window molding member 4 has corner portions 11 by which the upper and side portions 5, 6 are continuously connected with each other, making it possible to provide a refined appearance along the corner portions 11. Moreover, as the weirs 8 along the side portions 6 are formed by the lip section 4b which is reinforced by the core element 22, it is possible to effectively prevent or suppress the deformation of the lip section 4b even when it is subjected to external force, and to stably maintain the desired shape of the weirs 8 for a long period. The configuration, structure, material, etc., of the molding member 4 are not limited to those illustrated in the drawings, for which various modifications may be made. Similarly, various processes may be used to form the elongate member 35B and to deform the lip section 4b. For example, the molding member 4 according to the present invention may be used in conjunction with an automobile rear window plate, with the lip section defining a weir along the upper portion to prevent the rain water on the roof panel from flowing across the upper portion onto the rear window plate. The above-mentioned embodiment of the method according to the present invention, wherein the elongate member 35B as extruded has the cross-section of the side portions 6 throughout its entire length and is then subjected to a local plastic deformation of the lip section 4b to have the cross-section of the upper portion 5, is also subject to modifications. More particulalry, the extruded elongate body 35B may have the cross-section of the upper portion 5 throughout the entire length, and may be subjected to a local plastic deformation of the lip section 4b to have the cross-section of the side portions 6. Alternatively, the elongate member 35B may have an intermediate cross-section that the lip section 4b is slightly spaced from the outer surface of the window plate 2, and may be subjected to deformation of the lip section 4b along the entire length to have the cross-section of the upper portion 5 and side portions 6. Furthermore, the die plates in the shaping device 42, particularly the upper die plate 44, should have an outer surface which effectively prevents the elongate member 35B from becoming scratchy during the axial bending thereof. Thus, the die plates may be formed of synthetic resin material with a low friction resistance as well as a sufficient hardness, or may be formed of a metallic material whose surface to be brought into contact with the elongate member 35B is like a mirror-finished surface. Although the deformation of the lip section 4b is advantageously carried out simultaneously with the axial bending, depending upon the cross-sectional shape of the window molding member 4, the section 4b may be deflected and deformed downwardly by lowering a separate upper die plate after the axial bending. Finally, when there is a fluctuation or difference in the distance between the front or rear pillars of the automobile body panel, the molding member may be divided into separately prepared right and left molding halves, which are to be connected at the center of the upper edge of the window plate by using a connector. Even with this arrangement, an uninterrupted connection along the corner portions of the molding member, between the upper and side portions thereof, provides a more refined appearance as compared with the conventional molding member which includes separate connection pieces along the corner portions whereby the connections between the upper and side portions are interrupted. It will be readily appreciated from the foregoing detail description that, according to the present invention, the lip section and the core element are subjected to a plastic deformation to define the weirs along the side portions or upper portion for preventing the flow of rain water across the relevant portion. Such a novel structure of the window molding member is realized with a minimized number of components of a simplified structure, is easy to produce and assemble, and is capable of suppressing undesirable deformation of the lip section even when it is applied with external force, and maintaining the desired shape of the weirs in a stable manner and for a long period. Moreover, the core element arranged also in the lip section effectively prevents or suppresses undesired deformation thereof during the axial bending of the elongate member, and makes it possible to plastically deform the lip section to define the weirs without requiring heat treatment or the like specific measures.

Claims: A window moulding member, for instance for automobiles, comprising: a main body (4a) comprising a continuous elongate member including an upper portion (5) to extend along an upper edge of a window plate (2), at least one side portion(6) to extend along a side edge of said window plate (2) and at least one corner portion (11) integrally joining said upper and side portions (5,6), said main body having a longitudinal shape corresponding to the edge of said window plate (2); a lip section (4b) extending along the entire length of the main body (4a) and integral therewith; a core element (22) integrally provided with the main body and extending into the lip section (4b); said core element (22) having been deformed plastically, at least locally in the longitudinal direction of the core element (22), such that said moulding member has different cross-sections in said upper and side portions (5,6) and gradually changes cross-section substantially through said corner portion (11) to define, when said moulding member is mounted in place, at least one weir (8) along either said upper or side portion (5,6) to guide rain water along the weir and prevent it from flowing across the moulding member. The moulding member as claimed in claim 1, wherein said main body is composed of an extruded synthetic resin material. The moulding member as claimed in claim 1 or 2, wherein said core element (22) is composed of flexible profiled metal. The moulding member as claimed in claim 1, 2 or 3, wherein said core element (22) has a folded portion (24) where the core element (22) is subjected to said plastic deformation. The moulding member as claimed in claim 1, 2, 3 or 4 wherein said core element (22) includes an ornamental portion (23) which is visible from outside of said main body (4a). The moulding member as claimed in claim 5, wherein said ornamental portion (23) is formed of that portion of said core element (22) which is exposed outside of said main body (4a). The moulding member as claimed in claim 5, wherein said main body includes a transparent resin layer (25), and said core element (22) is completely embedded in said main body (4a) with said ornamental portion (23) being covered by said transparent resin layer. A method of manufacturing window mouldings, for instance for automobiles, comprising the steps of: forming a main body (4a) composed at least partly of a continuous elongate material, including an upper portion (5) to extend along an upper edge of a window plate (2), at least one side portion (6) to extend along a side edge of the window plate (2), and at least one corner portion (11) connecting said upper portion (5) and said side portion (6) with each other, the main body further including an integral lip section (4b) formed to extend over the entire length thereof, and a core element (22) integrally provided with the main body (4a) and extending into said lip section (4b); axially bending said main body (4a) into a shape corresponding longitudinally to the contour of said window plate (2); and plastically deforming said core element (22), at least locally in the longitudinal direction of the core element, so that the moulding member has different cross-sections in the upper and side sections (5,6) and gradually changes cross-section substantially through the corner section (11) to define at least one weir (8), when the moulding member is mounted in place, along either said upper portion (5) or said side portion (6) to guide rain water along the weir (8) and prevent it from flowing across the moulding member. The method as claimed in claim 8, wherein said step of forming the main body comprises extrusion of a synthetic resin material. The method as claimed in claim 9, wherein said synthetic resin material is co-extruded with said core element, which is composed of profiled metal. The method as claimed in claim 8, 9 or 10 wherein said step of subjecting the core element (22) to said plastic deformation is carried out substantially simultaneously with said step of subjecting the main body (4a) to said axial bending.

Inventors: FUJIOKA SAKAE C O HASHIMOTO FO, TAMURA TATSUYA C O HASHIMOTO F, FUJIOKA, SAKAE C/O HASHIMOTO FORMING IND. CO. LTD., TAMURA, TATSUYA C/O HASHIMOTO FORMING IND. CO. LTD
Applicants: HASHIMOTO FORMING KOGYO CO, HASHIMOTO FORMING INDUSTRY CO  LTD
Application year: 1988
Main classification: B60R13
IPC codes: B29C70, B60J10, B60J1, B29D99