Abstract:
Disclosed is a unitary cowl top ventilation component for a motor vehicle. The component includes structural and elastomeric portions molded into a single unitary body. Also disclosed are methods for making the component.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 11/762,971 filed Jun. 14, 2007, which claims priority of U.S. Provisional Patent Application Ser. No. 60/813,742 filed Jun. 14, 2006, entitled “Motor Vehicle Component and Method.” 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to nonmetallic components of motor vehicles and to methods for their manufacture. More specifically, the invention relates to injection molded components of motor vehicles, comprising rigid, structural polymeric members having integral seals, formed from an elastomeric polymer, bonded thereto. Most specifically, the invention relates to a cowl top ventilator component for a motor vehicle and to methods for its manufacture. 
       BACKGROUND OF THE INVENTION 
       [0003]    The cowl top ventilator is a component of a motor vehicle which operates to bridge the space between the windshield, hood and other body components of the motor vehicle while allowing for entry of outside air into the heating, ventilation and air conditioning system of the vehicle. The cowl must further operate to prevent exhaust and other vapors from the engine compartment from entering the passenger cabin of the motor vehicle. The cowl component must further operate to exclude water from the passenger cabin and from the engine compartment of the vehicle. In the prior art, such cowl top ventilator assemblies were typically multicomponent structures fabricated from a rigid structural material such as metal or a high strength polymer, and further incorporating a plurality of separate sealing gaskets. The multipart nature of these assemblies complicates the inventory, handling and installation of the cowl top ventilators, and can also lead to problems with the quality of the water or gas-tight seal provided thereby. As a consequence, such assemblies are costly and difficult to use. 
         [0004]    As will be explained in detail hereinbelow, the present invention provides for a unitary cowl top ventilator component which is fabricated from a high strength structural polymer and includes a series of integral seals, comprised of a polymeric material, molded thereonto. The components of the present invention are preferably manufactured by a multiple shot injection molding process which provides for a tight, fusion bond between the structural material and the elastomeric sealing material. As a consequence, high quality, integral, permanently bonded seals are provided. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0005]    Disclosed herein is a unitary cowl top ventilator component for a motor vehicle. The component includes a body of a rigid polymeric material which defines a structural member of the component. The cowl further includes a first body of an elastomeric polymer bonded to a first portion of the structural member. The first body of elastomeric material defines a first sealing member which is configured to engage a windshield of a motor vehicle. The cowl further includes a second body of an elastomeric polymer bonded to a second portion of the structural member. The second body of elastomeric material defines a second sealing member which is configured to engage a hood of a motor vehicle. In some instances, the cowl may further include a portion which is configured to support a seal which engages a plenum of a motor vehicle. This seal may be a body of an elastomeric polymer integrally molded onto the cowl, or it may comprise a separately affixed body of material such as a body of a foamed polymer. 
         [0006]    The seal which engages the windshield may comprise a flange which engages a face of the windshield. It may additionally, or alternatively, comprise a body which engages an edge of the windshield. The seal which engages the hood may comprise a bulb, a bead, a blade, a ridge, or any other such feature. In one specific instance, the seal is a hybrid seal which comprises an elastomeric blade which engages the hood, and operates in conjunction with a projecting blade portion of the structural member which underlies the elastomeric body and provides it with stiffness and resiliency. The cowl may further include features such as attachment hooks, brackets, and the like integrally molded thereonto or affixed by adhesive or fusion bonds. The cowl may be further configured to include openings having seals which allow for the pivotal motion of a portion of a windshield wiper assembly. 
         [0007]    In particular instances, the elastomeric material comprises natural rubbers, synthetic rubbers, elastomeric copolymers and the like taken either singly or in combination. The rigid polymer comprising the structural member may be a structural polymeric material such as nylon, ABS, polypropylene, TPO, ASA PC, and combinations thereof, and this polymer may be reinforced with a particulate or fibrous material. 
         [0008]    In specific instances, the cowl of the present invention is manufactured by an injection molding process, and in specific instances, this injection molding process is a multiple shot injection molding process which, in some instances, may be implemented utilizing a retracting blade, a sliding member, or similar structures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of one embodiment of cowl structured in accord with the present invention; 
           [0010]      FIG. 2  is a cross-sectional view of a windshield-engaging portion of a cowl; 
           [0011]      FIG. 3  is a perspective view, in partial cross section, of a portion of the window-engaging portion of a cowl member; 
           [0012]      FIG. 4  is a cross-sectional view of a portion of a cowl member shown as being in engagement with a portion of a hood of a motor vehicle; 
           [0013]      FIG. 5  is an enlarged, perspective view, in partial cross section, of a portion of the hood seal of the  FIG. 4  embodiment; 
           [0014]      FIG. 6  is a cross-sectional view of the seal of  FIG. 5  taken along line A-A; 
           [0015]      FIG. 7  is a perspective view, in partial cross section, of a hybrid hood seal in accord with the present invention; 
           [0016]      FIG. 8  is a cross-sectional view of a portion of a cowl showing the hood seal and plenum seal thereof; 
           [0017]      FIG. 9  is a schematic depiction of a first step in a molding process as being implemented to manufacture the cowl of  FIG. 2 ; 
           [0018]      FIG. 10  is a depiction of the second step in the molding process of  FIG. 9 ; 
           [0019]      FIG. 11  is a schematic depiction of a retracting blade molding process as being implemented to manufacture the windshield sealing portion of the cowl of  FIG. 3 ; and 
           [0020]      FIG. 12  is a depiction of the second stage in the molding process of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    As mentioned above, cowl top ventilator assemblies in accord with the present invention are fabricated from a combination of rigid and elastomeric polymeric materials, through the use of a multiple injection molding process. This process produces unitary bodies having rigid, structural and elastomeric sealing portions configured to provide a cowl member for a motor vehicle. The cowls made in accord with the present invention may have various configurations depending upon the configurations of the vehicles in which they are being incorporated. As such, it is to be understood that this disclosure utilizes some specific embodiments of the invention to illustrate the general purposes thereof, and the invention may be implemented in otherwise configured embodiments and/or may utilize processes and materials other than those specifically shown herein. 
         [0022]    Referring now to  FIG. 1 , there is shown one specific embodiment of a cowl top ventilator assembly  10  in accord with the present invention. The cowl  10  includes a body or structural portion  12  which is fabricated from a rigid polymeric material, as will be described hereinbelow. The cowl  10  includes a first elastomeric portion, also termed a window seal  14 , which extends along a first edge thereof. As will be explained hereinbelow, this window seal (also termed a lace) is configured to engage the front windshield of a motor vehicle (a windshield portion of which is shown in phantom outline) and form a water-resistant seal thereto. Projecting from an opposite edge is a hood seal  16 . This seal is also fabricated to include an elastomeric portion, and when the cowl  10  is installed in a motor vehicle, this hood seal  16  engages the vehicle&#39;s hood forming an environmental seal for the engine compartment. In the illustrated embodiment a projecting portion of the cowl  10  disposed beneath the hood seal  16  is configured to seal the cowl  10  to a plenum of the motor vehicle. The plenum seal may be comprised of a body of elastomeric material integrally molded onto the cowl  10 ; but, in other instances, the seal may be a separately applied piece of material such as a foam strip. In the illustrated embodiment, the cowl  10  further includes pivot seals  20  for engaging a windshield wiper mechanism of the motor vehicle. These pivot seals  20  are configured as openings formed in the body  12  of the cowl  10 , and further include an elastomeric sealing gasket disposed about the circumference of the opening. The windshield wiper pivot seals  20  are optional elements in the cowl, and may be omitted or otherwise disposed. As will be explained in further detail, the cowl may include yet other features, such as attachment clips and the like, and these features may be integrally molded thereonto. 
         [0023]    Referring now to  FIG. 2 , there is shown a cross-sectional view of a portion of the windshield-engaging section of a particular cowl top ventilator component of the present invention. The illustrated portion of the cowl  10  is comprised of a structural body member  12 , typically fabricated from a high strength polymer such as nylon, ABS, polypropylene, ASA, PC, other thermoplastic polyolefins (TPO) or the like. This polymer may, as is known in the art, be reinforced with a material such as glass fiber, carbon fiber, mineral material, metallic material or the like, so as to increase its strength. As shown in  FIG. 2 , the structural member  12  includes a channel portion  22  which is configured to engage the windshield of a motor vehicle. Integral with, and bonded to, the channel portion  22  is a body of elastomeric polymer  14  which forms a sealing member which engages a windshield (not shown). A first portion of the elastomeric body  14  engages an edge of the windshield, and a second portion forms a front, flange-like seal which contacts the face of the windshield, proximate at least one edge thereof. As shown herein, the two sealing portions are contiguous, although it is to be understood that they may be separate bodies. The thermoplastic elastomeric material may comprise natural rubbers, synthetic rubbers, copolymers, as well as any other natural or synthetic material providing the requisite combination of strength and resiliency. 
         [0024]    The  FIG. 2  embodiment shows an elastomeric window seal that contacts an edge and front surface of the windshield; in other embodiments, this seal may be otherwise configured. Referring now to  FIG. 3 , there is shown a perspective view, in partial cross section, of a portion of another cowl assembly  10  in which the windshield-engaging portion is configured so that an elastomeric body establishes only edge contact with the windshield. Specifically, the embodiment of  FIG. 3  includes a structural member  12 , fabricated from a rigid polymeric material as described hereinabove. Bonded to an edge of the structural member  12  is a blade-like elastomeric body  24 , as described above. The elastomeric body  24  is configured to provide a seal to the face of a windshield. As is seen in the cross-sectional portion of the  FIG. 3  illustration, the interface  26  between the edges of the structural member  12  and the elastomeric body  24  is a step interface. This type of interface enhances the contact area, and hence the adhesion between the two bodies. As further illustrated, the  FIG. 3  embodiment includes an attachment hook  28  which is integrally molded with the structural body  12 . Other attachment features such as channels, tabs, and the like may be likewise included. In some instances, attachment members may be formed to include a living hinge which joins them to the remainder of the structural member  12 . In yet other instances, attachment members may comprise separately affixed bodies joined in the structural member by means including, but not limited to, adhesive, adhesion bonding, mechanical connectors and the like. In view of  FIGS. 2  and  3 , it is to be understood that yet other configurations of windshield engagement portions may be implemented. For example, some embodiments may eliminate front face contact with the windshield and rely solely upon edge contact. All such embodiments are within the scope of this invention. 
         [0025]    Referring now to  FIG. 4 , there is shown a cross-sectional view of a portion of a cowl  10  which is configured to engage the hood,  30 , of a motor vehicle. Shown in the  FIG. 4  embodiment is a structural portion  12  as previously described which includes an integrally molded hood seal  16  fabricated from an elastomeric material. In the illustrated embodiment, the hood seal  16  is configured as a hollow, elastomeric bead, also referred to as a bulb seal, which engages, and is compressed by, a portion of the hood  30 . In other embodiments, the hood seal may be otherwise configured. For example, the hood seal may comprise a projecting, elastomeric, blade, a solid bead, a series of blades, beads or other such features, as well as variations thereof. 
         [0026]    In the illustrated embodiment, the structural body  12  is configured to include a portion which projects beneath the hood seal  16 . This portion is configured to engage the plenum of the motor vehicle and to provide an environmental seal between the engine compartment and passenger compartment. In that regard, the plenum-engaging portion may include a further sealing member  32 . This seal  32  may, in some instances, be an integrally formed body of elastomeric material as described above, and in that regard, may be variously configured. In other instances, the plenum seal may be provided by a body of foamed polymer adhesively affixed to the plenum-contacting portion of the structural member  12 . It should be noted that the illustration of  FIG. 4  is intended only to show the general principles of the invention. Depending upon particular configurations of the motor vehicle, the relative size, placement and direction, orientation of the various components will differ. 
         [0027]    Referring now to  FIG. 5 , there is shown an enlarged, partially cross-sectional, perspective view of a hood seal  16  and the associated portion of the structural member  12  of the cowl  10 . As illustrated in  FIG. 5 , the structural member  12  includes a plurality of crossbar sections  34  which are disposed so as to bridge portions of the slot  36  into which the elastomeric material of the hood seal  16  is molded. These crossbar portions  34  give additional strength and rigidity to the cowl, and further serve to strengthen the bead  16  so as to prevent undue collapse or set during its service life. 
         [0028]    Referring now to  FIG. 6 , there is a shown a cross-sectional view of the segment of the cowl  10  of  FIG. 5 , taken along line  6 - 6 . As will be seen in  FIG. 6 , the crossbar portion  34  of the structural body bridges the two portions of the body  12 , but does not project into the seal portion  16 . This structure can be achieved by the use of a finger type lifter in the molding apparatus. A seal configured as per  FIGS. 4-6 , also termed a “bulb seal” combines rigidity and resiliency and is operable to provide a good sealing action under a variety of environmental conditions. In other embodiments, the structural member may be configured so that the entire body of the hood seal is backed by solid material. In yet other instances, reinforcement of the hood seal may be provided by an insert of yet a different material such as a metallic body, another polymeric body, or the like. Also, as noted above, the hood seal may be fabricated as a solid body of elastomeric material. 
         [0029]    Referring now to  FIG. 7 , there is shown yet another embodiment of a hood seal design referred to as a “hybrid” hood seal. The  FIG. 7  embodiment is a partial perspective view, in cross section, of a cowl  10  showing a hybrid hood seal configuration in which sealing of the hood is accomplished by a body of elastomeric material  38  which is configured as a blade-like member. Underlying major portion of the elastomeric material is a blade-like extension portion  40  of the material comprising the structural member  12 . In the operation of this seal, elastomeric material  38  provides a tight environmental seal against the hood, while the extension portion  40  stiffens and supports the elastomeric material  38  while allowing for some flexibility. This combination of materials and properties in this hybrid seal prevents the elastomeric body from taking a set during its service life and provides for the long-term reliability of the hood seal. 
         [0030]    Referring now to  FIG. 8 , there is shown a cross-sectional view of a portion of a cowl  10  which portion includes a hood seal  42  and a plenum seal  44 . As shown in  FIG. 8 , the cowl  10  has a structural body  12  which includes a blade-like hood seal  42  thereupon. This seal  42  is bonded to the structural body  12  via a step joint  46  which increases the contact thereof between the two materials. In other embodiments, this joint may be variously configured. The  FIG. 8  embodiment further includes a plenum seal  44  which is comprised of an elastomeric material integrally molded onto the structural body  12 . 
         [0031]    Cowls in accord with the present invention may be yet otherwise configured. As discussed above, the cowls may include further features such as windshield wiper seals, attachment hooks or other mounting hardware, and the like. In the typical assembly of motor vehicles, cowls are used in combination with end boots which operate to join the cowl to the remainder of the vehicular structure. In accord with the present invention, such end boot members may be formed as integral portions of the cowl during the molding process used for cowl fabrication. Alternatively, the end boots may be formed as separate members, and in that regard, the cowls of the present invention may include coupling features such as latches, hooks, mounting hardware, and/or elastomeric sealing members. 
         [0032]    Various processes may be used to fabricate the components of the present invention. Injection molding is one particular method which may be employed, and multiple shot injection molding is a specific type of injection molding which may be used with advantage in the present invention. In such processes, different types of molding material may be simultaneously or sequentially injected into a mold to fabricate unitary articles having different types of material fusion bonded to one another. Within the context of this disclosure, fusion bonding shall refer to bonds formed by contacting bodies of material together when at least one of those materials is in a molten state. 
         [0033]      FIG. 9  is a schematic depiction of a first step in a general, multi-shot molding process wherein articles comprising different polymeric materials in accord with the present invention may be fabricated. Such molding processes are generically referred to as retracting blade processes, since a retractable masking blade, slide or other such member is employed to control the flow of different molding materials into a mold cavity. As is shown in  FIG. 9 , a structural member of the component is formed in a first step by injection molding a high strength polymeric material into a mold cavity.  FIG. 9  shows only a portion of the structural component, in this instance the window channel portion of the  FIG. 2  embodiment, although it is to be understood that the entire structural member is molded in this first step. As will be seen, the molding apparatus includes a first slide member  50  which engages and defines a portion of the structural member. The structural member  12  is formed by injecting a first molten polymeric material into the mold cavity from a first injection port (not shown). As will be explained in detail below, the slide  50  will be moved in subsequent steps. The slide  50  includes a gate  52 , termed a cashew gate, which provides a second injection port and which in subsequent steps will operate to deliver a second molding material to the system. This gate  52  is in communication with a source of elastomeric polymeric material  54 , but in the  FIG. 9  configuration it is in a forward position and not operable to deliver polymeric material thereto. 
         [0034]    Referring now to  FIG. 10 , there is shown a subsequent step in the operation which is carried out after the injection of the material comprising the structural member  12 . In this stage of the process, the slide  50  is withdrawn thereby defining a further mold cavity corresponding to the aforedescribed seals. By withdrawing slide  50 , the injection gate  52  is placed in communication with the source of elastomeric polymer  54 , and this material is then injected into the newly opened cavity so as to form the elastomeric portions of the cowl. The result of this process is that elastomeric polymer is fusion bonded to the high strength structural polymer thereby providing a composite component having structural integrity and integral sealing members. 
         [0035]    Referring now to  FIGS. 11 and 12 , there is shown a composite molding process adopted for the manufacture of the  FIG. 3  windshield seal portion of the cowl. As shown in  FIG. 1 , the molding apparatus is provided having a molded cavity defined by an upper mold element  60 , a lower mold element  62 ; and in this embodiment, a core lifter  64  is also included to accommodate the molding of the hook portion of the cowl. The apparatus of  FIG. 11  further includes a retracting blade  66  disposed so as to close off a portion of the mold cavity when disposed in its unretracted position. In a first step of the process, as is shown in  FIG. 11 , the structural member  12  is molded by injecting a high strength thermoplastic material into the mold cavity through injector  65 . The presence of the retractable blade  66  prevents this first material from entering the seal-defining portion of the mold cavity  68 . Following the injection of the first material, and is shown in  FIG. 12 , the blade  66  is withdrawn so as to open the seal portion of the cavity, and the second, elastomeric material is injected therein through injector  67 , so as to form a resilient, fusion-bonded body with the first portion. After completion of the second step, the article is removed from the mold. Similar processes may be used to form other portions of the cowl. For example, the techniques described hereinabove can be used to form integral sealing gaskets for accommodating windshield wipers. Likewise, these techniques may be used to form plenum seals. While all the foregoing has described molding processes utilizing two different materials, one of which is a high strength structural polymer and the other is a resilient, elastomeric material, it is to be understood that the aforedescribed process may be extended to the manufacture of items having three or more different polymeric materials incorporated therein. For example, articles may be fabricated utilizing elastomeric materials of different durometer readings. Likewise, the structural portion of the component may be prepared from different materials for purposes of appearance, differential strength, and the like. For example, a structural core may be over molded with a surface coat to provide for paintability, appearance, or the like. Also, areas of the cowl requiring very high strength could be molded from very high strength polymers, while other portions requiring lesser strength could be molded from lower strength materials. All such embodiments are within the scope of this invention. 
         [0036]    The foregoing represents some particular systems for fabricating the component of the present invention. Other molding systems, including transfer molding systems and rotational molding systems, as well as yet other systems operative to mold multimaterial articles, may be adapted for the practice of the present invention. 
         [0037]    In view of the foregoing, it will be appreciated by one of skill in the art that yet other embodiments and modifications of the system may be implemented. Therefore, it is to be understood that the foregoing drawings, discussion and description are illustrative of particular embodiments of the invention, but are not meant to be limitations upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.