Abstract:
A vehicle weatherstrip, beltstrip or door seal includes a hybrid carrier or core and extruded or molded elastomeric sealing features. The hybrid carrier includes lineal sections of diverse flexibility and compressibility which are achieved by upsetting the metal carrier by lancing, stamping or coining and, optimally, stretching. Preferably, the carrier is manufactured in a continuous length, the elastomeric material is extruded or molded thereover and the resulting product is cut into useable lengths having the desired more flexible and more rigid regions disposed along its length which correspond to corners and straight sections, respectively, of for example, a glass run.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The invention relates generally to weatherstrips for motor vehicles and more particularly to weatherstrips, beltstrips and door seals for motor vehicles having a metal core or carrier exhibiting lineal regions of diverse rigidity and compressibility.  
         [0002]     Weatherstrips and beltstrips have long been utilized by automobile manufacturers to seal between a fixed or movable glass light and the adjacent vehicle panel such as a door or door frame. Generally speaking, a weatherstrip refers to that portion of the seal extending vertically up one side of a window light, across the upper portion and down the opposite side. Typically as well, these weatherstrips extend well into the door to serve as tracks or rows for the window when it is lowered and retracted into the door. A beltstrip refers to that sealing component which extends across the lower portion of the window opening from one vertical edge of the opening to the other and seals and aesthetically finishes the region between the door and the window light. A door seal, as the name suggests, refers to the seal between a door and the vehicle body.  
         [0003]     Particularly with regard to the weatherstrip, many competing engineering and aesthetic demands must be considered. Perhaps of greatest importance is the necessity to achieve an air and water tight seal around the glass and between the weatherstrip and the door frame such that both the ingress of water and the generation of wind noise are completely eliminated. Second of all, the weatherstrip must provide an aesthetically pleasing appearance to the door frame. Thirdly, it must conform to both the shape of the door frame and the glass and provide a suitable and uniform track in which the glass is received and translates.  
         [0004]     One of the challenges of the last consideration is the desire to provide significant rigidity to the weatherstrip in regions where the weatherstrip it is substantially straight such as the front and back vertical runs as well as the upper horizontal run and also permit the bending or forming of the weatherstrip to conform to corners of the window and window frame and any other curves or non-linear portions of the window and frame dictated by aesthetics or mechanical considerations.  
         [0005]     In the past, such weatherstrips have frequently been fabricated of an internal metal core and outer molded elastomeric material. To accommodate the straight and curved sections, the metallic core was assembled from a plurality of short sections having a desired flexibility or rigidity.  
         [0006]     The present invention represents a significant improvement over such weatherstrips or beltstrips having cores assembled from a plurality of sections.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     A vehicle weatherstrip, beltstrip or door seal includes a hybrid carrier or core and extruded or molded elastomeric sealing features. The hybrid carrier includes lineal sections of diverse flexibility and compressibility which are achieved by upsetting the metal carrier by lancing, stamping or coining and, optimally, stretching. Preferably, the carrier is manufactured in a continuous length, the elastomeric material is extruded or molded thereover and the resulting product is cut into useable lengths having the desired more flexible and more rigid regions disposed along its length which correspond to corners and straight sections, respectively, of for example, a glass run.  
         [0008]     Thus it is an object of the present invention to provide a motor vehicle weatherstrip, beltstrip or door seal having a carrier or core exhibiting diverse flexibilities.  
         [0009]     It is a further object of the present invention to provide a motor vehicle weatherstrip, beltstrip or door seal having a carrier or core exhibiting diverse compressibilities.  
         [0010]     It is a still further object of the present invention to provide a weatherstrip, beltstrip or door seal having a metal core or carrier with distinct regions of greater or lesser flexibility which is encapsulated by molding or extruding within elastomeric sealing material.  
         [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 perspective view of a typical motor vehicle door having a weatherstrip according to the present invention disposed thereon;  
         [0013]      FIG. 2  is a perspective view of a motor vehicle weatherstrip according to the present invention with a portion of the seal material removed;  
         [0014]      FIG. 3  is an enlarged perspective view of a motor vehicle weatherstrip according to the present invention with a portion of the seal material removed;  
         [0015]      FIG. 4  is an enlarged, plan view of a first alternate embodiment carrier or core of a motor vehicle weatherstrip according to the invention;  
         [0016]      FIG. 5  is an enlarged, plan view of a second alternate embodiment carrier or core of a motor vehicle weatherstrip according to the present invention;  
         [0017]      FIG. 6  is an enlarged, plan view of a third alternate embodiment carrier or core of a motor vehicle weatherstrip according to the present invention having a portion removed;  
         [0018]      FIG. 7  is a diagrammatic view of motor vehicle and doors with the present invention utilized as a motor vehicle door seal; and  
         [0019]      FIG. 8  is an enlarged perspective view of a motor vehicle door seal according to the present invention with a portion of the seal material removed. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0020]     Referring now to  FIGS. 1 and 2 , a typical door for a motor vehicle such as a passenger car, sport utility vehicle (SUV), station wagon or pick-up truck is illustrated and designated by the reference number  10 . The door  10  includes an upper freestanding frame portion  12  which extends from a lower panel section  14 . The frame portion  12  and the lower panel section  14  cooperatively define a window opening  16  which receives a window or glass light (not illustrated). It will be appreciated that the frame portion  12  includes curved regions  18  of relatively small radii interconnecting straight or relatively straight regions. Extending about the interior of the window opening  16  and depending into and secured to the lower panel section  14  is a weatherstrip assembly  20 . Preferably, the weatherstrip assembly  20  includes mounting clips or brackets  22 . The mounting clips or brackets  22  may either be formed integrally with the weatherstrip assembly  20  or secured thereto mechanically or by a compatible adhesive. Threaded fasteners  24  which extend through suitably sized openings  26  in the mounting brackets or clips  22  secure the lower portions of the weatherstrip assembly  20  to the lower panel section  14 .  
         [0021]     Referring now to  FIG. 3 , the weatherstrip assembly  20  includes a metal core or carrier  30  having regions of diverse flexibility and compressibility. For example, the metal carrier  30  includes a first region  32  of lower flexibility, i.e., higher rigidity. Such region  32  may be achieved by no or little mechanical modification of the carrier or core  30 . For example, as illustrated in  FIG. 3 , relatively small, alternating and discontinuous apertures or slots  34  may be formed in the carrier or core  30  to provide minimally reduced rigidity, i.e., enhanced flexibility, from its continuous, unaltered condition. Such apertures or slots  34  also assist in achieving intimate bonding between the carrier or core  30  and molded or extruded elastomeric material  40  which encapsulates the carrier or core  30 . Alternatively, and as illustrated in  FIG. 4 , the carrier or core  30  may be undisturbed (solid) and thus generally exhibit maximum rigidity and minimum flexibility and compressibility. Preferably, the core or carrier  30  is fabricated of steel or aluminum. Other materials having similar strength and toughness such as certain plastics may also be utilized.  
         [0022]     In an adjacent, more flexible region  36 , a plurality of larger slits  38  which extend to the edges of the core or carrier  30  and central intermediate slots  42  which provide significantly greater flexibility, i.e., lower rigidity, and increased compressibility. It will be appreciated that the less flexible, i.e., more rigid, and less compressible regions  32  preferably correspond to the straight or substantially straight regions of the weatherstrip assembly  20  illustrated in  FIG. 1  between the curved regions  18  which correspond to the regions  36  of greater flexibility, i.e., less rigidity, and more compressibility of the core or carrier  30 . It will be appreciated that the slots  34  and the larger slits  38  and  42  illustrated in  FIG. 3  are illustrative only and that numerous and various patterns and configurations of variously oriented slots, slits, polygonal openings, achieved by stamping, lancing, coining and stretching, which provide diverse linear regions of distinct flexibilities along the core or carrier  30  are all deemed to be within the purview of this invention.  
         [0023]     The elastomeric material  40  which may be molded or extruded about the core or carrier  30  typically will include a first or inner flange  42  which engages an inner portion of the frame portion  12  and a second or outer flange  44  which engages an exterior portion of the frame portion  12 , illustrated in  FIG. 1 . It should be appreciated that the configuration, especially with regard to the flanges  42  and  44  of the weatherstrip assembly  20  is illustrative of weatherstrip assemblies in general and is not intended to be limiting. In this regard, while this description refers to the assembly  20  as a weatherstrip, it should be appreciated that the invention applies equally well to and may be utilized with a beltstrip. The elastomeric material  40  is preferably, approximately 70 durometer in hardness and may be selected from a number of elastomers and thermoplastics such as EPDM, TPE, and TTE, for example. If desired, a surface treatment such as flocking may be disposed in the glass nun or channel  46 .  
         [0024]     Referring now to  FIG. 4 , a first alternate embodiment of the core or carrier  30  is illustrated and designated by the reference number  30 A. The first alternate embodiment carrier  30 A includes a less flexible, i.e., more rigid, region  52  which is undisturbed (solid) material. It also includes a second more flexible, i.e., less rigid, and more compressible region  54  having slits  56  which extend transversely inwardly from its edges as well as both transversely and longitudinally intermediately disposed arcuate slots  58 . If desired, the more flexible region  54  may be stretched or expanded longitudinally to increase the widths of the slits  56  and the arcuate slots  58  to further increase flexibility and compressibility. As noted above, regions such as the region  52  which lacks through openings in the carrier core  30 A, typically require a metal primer and/or adhesive to suitably and appropriately secure the extruded or molded elastomeric material  40  to the carrier or core  30 A in regions such as the low flexibility region  52 .  
         [0025]     Referring now to  FIG. 5 , a second alternate embodiment core or carrier  30 B is illustrated. Once again, it includes a region  62  of less flexibility, i.e., greater rigidity, and less compressibility which is defined by a plurality of through apertures  64 . The through apertures  64  are preferably aligned in uniform columns and occupy the center portion of the carrier or core  30 B but not the outer, edge adjacent regions. The apertures  64  thus facilitate intimate and positive bonding between the elastomeric material  40  and the core or carrier  30 B while the outer, solid region of the core  30 B provides appropriate rigidity to the region  62 .  
         [0026]     The core or carrier  30 B also includes a region  66  of increased flexibility, i.e., reduced rigidity, and increased compressibility which once again defines a plurality of parallel, transverse slits  68  which extend inwardly from the edges of the carrier or core  30 B. Disposed intermediate the slits  68  are arcuate slots  70 . As noted above, the regions  66  of increased flexibility may, if desired, be expanded or stretched to further reduce its rigidity and increase its flexibility and compressibility.  
         [0027]     Referring now to  FIG. 6 , a third alternate embodiment core or carrier  30 C is illustrated. Once again, it includes a region or regions  72  of lesser flexibility, i.e., greater rigidity, and less compressibility which is defined by a plurality of through slots  74 . The through slots  74  are preferably aligned in a uniform array. It will thus be appreciated that the slots  74  facilitate intimate and positive bonding between the elastomeric material  40  and the core or carrier  30 C.  
         [0028]     The core or carrier  30 C also includes a region  76  of enhanced flexibility, i.e., reduced rigidity, and increased compressibility which, first of all defines a plurality of parallel transverse slits  78  which extend inwardly from the edges of the core or carrier  30 C. The core or carrier  30 C also includes a skived region  84 , that is, a region  84  where a portion, e.g., approximately one half its width, has been removed along a portion of its length. The removal of such material as illustrated by the reduced width or skived portion  84  further reduces the rigidity of the core or carrier  30 C and increases its compressibility. Skiving of a portion of the core or carrier  30 C may be particularly useful when the frame portion  12  of the door (illustrated in  FIG. 1 ) which receives the weatherstrip assembly  20  includes oblique or angularly disposed regions which tilt or cant the weatherstrip assembly  20 .  
         [0029]     Referring now to  FIG. 7 , a sidewall portion  90  of a motor vehicle is schematically illustrated having a first door  92  and a second door  94 . Preferably secured to each of the doors  92  and  94  about their peripheries is a door seal assembly  100 .  
         [0030]     As illustrated in  FIG. 8 , the door seal assembly  100  includes a carrier or core  30 D which is essentially similar to the carriers or cores  30  and  30 B described above. As such, it includes a region  102  of less flexibility, i.e., greater rigidity defined by a plurality of through apertures  104  and a region  106  of greater flexibility, i.e., lesser rigidity, and greater compressibility defined by inwardly extending slits  108  as well as intermediate slots  110  or similar features. The core or carrier  30 D is encapsulated by molding or extruding with an elastomeric material  112 . The elastomeric material  112  is formed into a channel  114  which mimics the shape of the core or carrier  30 B which facilitates mounting and retention of the door seal assembly  100  upon complementarily configured features (not illustrated) of the vehicle doors  92  and  94  as well as a hollow, horseshoe or balloon shaped section  116  which is relatively very resilient and flexible and achieves a seal against an adjacent portion of the vehicle body when the doors  92  and  94  are closed. Once again, the relatively less flexible regions  102  of the door seal assembly  100  are utilized along straight or relatively straight regions of the doors  92  and  94  and the relatively more flexible and compressible regions  106  corresponds to curved regions of the peripheries of the doors  92  and  94 .  
         [0031]     Manufacture of the weatherstrip assembly  20  and the door seal assembly  100  will now be briefly described. Preferably, the core or carrier  30 ,  30 A,  30 B or  30 C is fabricated in a continuous, uninterrupted length having regions of lesser flexibility, i.e., greater rigidity, alternating with regions of greater flexibility, i.e., less rigidity. As noted, these regions may be achieved by stamping, punching, lancing, coining, and, if desired, stretching to achieve the desired degree of flexibility or rigidity. Next and preferably, the carrier or core  30 ,  30 B or  30 C is passed into an extruding machine where in the desired elastomeric material  40  or  112  is extruded onto the core or carrier.  
         [0032]     In the case of the core or carrier  30 A which contains a less flexible region  52  having no upset of the carrier or core  30 A, a metal primer and/or adhesive may be applied to ensure good adhesion of the elastomeric material  40  to the region  52 . By suitably timed or synchronized cutting mechanisms, or the use of an X-ray or metal density sensor driving a cutting mechanism, the weatherstrip assemblies  20  or door seal assemblies  100  may then be appropriately cut such that each assembly  20  and  100 , first of all, is of the desired and required length and, second of all, contains the appropriate number, length and location of more flexible and less flexible regions. Alternatively, the core or carrier  30 ,  30 A,  30 B and  30 C may be first cut into desired lengths at which time the elastomeric material  40  or  112  is then either extruded or molded about the cores or carriers. Finally, and if desired, flocking or other surface treatment (not illustrated) may be applied to the weatherstrip assembly  20  in desired regions.  
         [0033]     The foregoing disclosure is the best mode devised by the inventor for practicing this invention. It is apparent, however, that devices incorporating modifications and variations will be obvious to one skilled in the art of weatherstrips, beltstrips and door seals for motor vehicles. Inasmuch as the foregoing disclosure is intended to enable one skilled in the pertinent art to practice the instant invention, it should not be construed to be limited thereby but should be construed to include such aforementioned obvious variations and be limited only by the scope and spirit of the following claims.