Abstract:
An integrated windshield cowl and seal assembly includes a body of a rigid thermoplastic material and upper and lower forward and lower rear resilient seals bonded to the body. The seals may be either bonded by material compatibility or by mechanical, interlocking means. The cowl assembly according to the present invention significantly reduces the number of parts when compared to prior art assemblies. The cowl and seal assembly may also include fender closeouts which extend to the adjacent inner surfaces of the fenders and seal thereagainst.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The invention relates generally to cowls for motor vehicles and more specifically to an integrated cowl for a motor vehicle having a rigid body and upper, lower and rear resilient integrated seals.  
         [0002]     Motor vehicle, i.e., passenger car, pickup truck and SUV, designers have settled upon drawing air for heating, cooling and ventilating the passenger compartment of the motor vehicle through the gap between the rear of the hood and the windshield. This region also houses and accommodates the windshield wipers and often washer jets. As such, the cowl must perform several functions: allow the ingress of fresh air, exclude debris and foreign objects such as leaves and twigs; cosmetically and aesthetically close or fill the gap between the windshield and hood; accept components of the windshield wiper and washer system and facilitate the off flow of water from the windshield.  
         [0003]     For many years, the cowl was metal and was generally horizontal and stationary; the hood aligning with the cowl when it was closed. Now, the cowl is generally plastic and may comprise numerous small pieces which are either assembled on the vehicle or are assembled into a complete cowl structure prior to installation. For example, separate left, center and right sections may include inserts for receiving windshield washer and wiper components as well as flexible seals.  
         [0004]     One of the design criteria which complicates the cowl is the necessity of providing a tight seal both against the windshield or windshield support structure at the rear of the cowl and also to the hood and adjacent structure at the front of the cowl in order to foreclose the ingress of foreign matter.  
         [0005]     From the foregoing, it is apparent that improvements in the art and design of motor vehicle cowls would be desirable.  
       SUMMARY OF THE INVENTION  
       [0006]     An integrated windshield cowl and seal assembly includes a body portion of a rigid thermoplastic material and upper and lower forward and lower rearward resilient seals bonded to the body portion. The seals may be either bonded by material compatibility or by mechanical, interlocking means. The cowl and seal assembly according to the present invention significantly reduces the number of parts when compared to prior art assemblies. The cowl and seal assembly may also include fender closeouts which extend to the adjacent inner surfaces of the fenders and seal thereagainst.  
         [0007]     It is thus an object of the present invention to provide an integrated motor vehicle cowl and seal assembly.  
         [0008]     It is a further object of the present invention to provide an integrated motor vehicle cowl and seal assembly wherein the cowl and seals are fabricated of distinct materials.  
         [0009]     It is a still further object of the present invention to provide an integrated motor vehicle cowl and seal wherein the materials of the cowl and seals are secured together.  
         [0010]     It is a still further object of the present invention to provide an integrated motor vehicle cowl and seal assembly including optional fender closeouts.  
         [0011]     Further objects and advantages of the present invention will become apparent by reference to the following description of the preferred embodiment and appended drawings wherein like reference numbers refer to the same component, element or feature. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a front view of a portion of a motor vehicle illustrating an integrated cowl and seal assembly according to the present invention;  
         [0013]      FIG. 2  is a plan view of an integrated motor vehicle cowl and seal assembly according to the present invention including fender closeouts;  
         [0014]      FIG. 3  is a full, sectional view of an integrated cowl and seal assembly taken along line  3 - 3  of  FIG. 2 ;  
         [0015]      FIG. 4  is an enlarged, full, sectional view of an integrated cowl and seal assembly according to the present invention; and  
         [0016]      FIG. 5  is a fragmentary, sectional view of an integrated cowl and seal assembly according to the present invention taken along line  5 - 5  of  FIG. 4 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]     Referring now to  FIG. 1 , a forward portion of a motor vehicle is illustrated and generally designated by the reference number  10 . The motor vehicle  10  includes a hood  12  which pivotally and selectively covers and closes an engine compartment (not illustrated), a right fender assembly  14 , a left fender assembly  16  and a windshield  18 .  
         [0018]     Extending transversely across the motor vehicle  10  between the hood  12  and the windshield  18  is an integrated cowl assembly  20 . In typical fashion, a pair of windshield wipers  22  are mounted upon and driven by shafts (not illustrated) extending through the cowl assembly  20 . The integrated cowl assembly  20  extends from the rear, underside of the hood  12  to the front of the windshield  18  and transversely, generally from the right fender  14  to the left fender  16 .  
         [0019]     Turning now to  FIG. 2 , the integrated cowl assembly  20  includes an elongate cowl structure or body  24  having suitably sized and disposed openings  26  for receiving windshield wiper drive shafts (not illustrated). The cowl body  24  also includes a plurality of variously configured transverse and longitudinal ridges, channels and troughs  28 , which define a plurality of through openings  32 , which facilitate the ingress of fresh air into the heating, ventilating and air conditioning system (not illustrated) of the motor vehicle  10 .  
         [0020]     Depending upon both the configuration of the motor vehicle  10  and the integrated cowl assembly  20 , the cowl assembly  20  may include left and right fender closeouts  34 . The left and right fender closeouts  34  are small end features of the integrated cowl assembly  20 , which may be either integrally formed therewith or separately fabricated and subsequently attached by known mounting and securing techniques such as autogenous bonding including RF or heat sealing or other methods such as the use of adhesives. The fender closeouts  34  close off or seal any open regions at the ends of the cowl body  24  adjacent the fenders  14  and  16  through which foreign matter, rodents or other undesirable material or substances might otherwise gain access to the vehicle ventilating, heating and air conditioning system.  
         [0021]     The cowl body  24  and the finder closeouts  34  are preferably fabricated of a rigid thermoplastic material such as acrylonitrile butadiene styrene (ABS), an acrylonitrile butadiene styrene/polycarbonate blend, a thermoplastic olefin (TPO) or other, similar thermoplastic materials. The term “rigid” as used herein means reasonably inflexible, reasonably resistance to impact and capable of supporting itself over the region (several feet by several inches) it extends.  
         [0022]     Referring now to  FIGS. 3 and 4 , the integrated cowl assembly  20  includes a first or forward flexible flange or seal  40  which is mechanically secured to the forward portion of the cowl body  24 , extends obliquely therefrom and engages the underside of the hood  12  to prevent the ingress of foreign objects and material, into the engine compartment of the motor vehicle  10 . The first or forward flange or seal  40  also includes a lower seal  44  depending from the cowl body  24 , which engages a metal flange, plate or member  45  disposed proximate the engine compartment of the motor vehicle  10 . Preferably, the cowl body  24  includes a plurality of small through openings  46  which receive threaded fasteners, Christmas tree (push-in) fasteners or similar removable fasteners  48  which secure the forward edge of the cowl body  24  to the metal member  45  of the motor vehicle  10 . Depending upon the configuration of the motor vehicle  10 , other securement means such as clips, adhesives, clamps, cowl receiving slots or magnets may be utilized to secure the cowl body  24  to the metal flange or member  45 .  
         [0023]     At the rear, lower edge of the cowl  24  is disposed a second or rear seal assembly  50 . The second or rear seal assembly  50  includes a body  52  narrowing to a flexible lip or flange  54  which engages the windshield  18  adjacent its lower gasket or seal  56 , which supports the windshield  18  on a transverse metal body member  58 . Both the front seal assembly  40  and the rear seal assembly  50  may be fabricated of a soft, flexible elastomer such as rubber, synthetic rubber, or a similar material.  
         [0024]     Preferably, the cowl assembly  20  is produced by sequential injection of a thermoplastic material to form the cowl body  24  and a compatible material to form the seal assemblies  40  and  50  such as a polypropylene filled thermoplastic elastomer (TPE), a thermoplastic olefin (TPO), a thermoplastic vulcanizate (TPV) or a combination thereof. Alternatively, the seal assemblies  40  and  50  can be fabricated of a non-compatible material (with the cowl body  24 ) and thus may be mechanically bonded (as shown) or secured with a suitable adhesive.  
         [0025]     Referring now to  FIGS. 4 and 5 , the first or forward seal assembly  40  is molded and preferably mechanically interlocked to the cowl body  24  by virtue of a plurality of spaced apart through apertures  60  formed therein adjacent the forward or leading edge of the cowl body  24 . The first or forward flange assembly  40  is thus preferably in-situ molded upon the cowl body  24  of the cowl assembly  20  and thus is retained thereon by the continuous upper flange  42 , the continuous lower flange  44  and the plurality of webs or sections extending through the plurality of apertures  60 .  
         [0026]     While this invention has been described in terms of certain embodiments thereof, it is not intended to be so limited, but rather should be limited only to the extent set forth in the claims that follow.