Abstract:
An apparatus and method for manufacturing a vehicle door barrier or shield for attachment to an inner door trim panel mountable on a vehicle door in which the barrier self-seals the opening between the vehicle door and the interior passenger compartment. The barrier is formed of a resilient gasket material that is shaped or formed with a peripheral rail or spring attachment surface that is compressed as the interior vehicle door trim panel is fastened to the interior surface of the door sheet metal to effect a watertight seal about the periphery of the door. The attachment surface carrying a seal material is disposed in an interference position with the door inner panel when the joined inner door trim panel and the barrier are mounted on the door inner panel. The interference deflects the attachment surface to create a joining force to secure the seal material to the door inner panel. The attachment surface may be a continuous shaped section of the barrier and/or a cantilevered edge portion of varying cross section.

Description:
BACKGROUND 
     The present invention is related to vehicle door water shield barriers, which prevent the ingress of water, sound, dirt and air into the vehicle passenger compartment. 
     It is known that a door water shield provides a water, sound, dirt and air barrier between the inner door trim panel and the inner metal panel of a vehicle door. Water shield barriers are made of a broad range of materials including stamped sheet metal, injection molded rigid plastic, resilient foamed and non-foamed plastics. The barriers also may be combined with other acoustic materials to provide sound attenuation in the vehicle passenger compartment. 
     Although the current state of the art production of the door water shield varies from one manufacturer to another, typically all manufacturers use a flat or formed sheet of resilient material with a peripheral band of adhesive or foam gasket designed to seal the water shield barrier material to the inner sheet metal of a vehicle door. An assembly line worker mounts the water shield on the door inner surface. The adhesive is then pressed onto the surface manually using a hand and/or by use of a wiping device to insure that the adhesive is bonded to the door sheet metal. In some applications, a mechanical pressurized roller system is used to firmly press the adhesive into place. In other applications, the assembly line worker may apply adhesive from a dispenser directly to the vehicle door, and then proceed as above to apply the water shield barrier to the adhesive and pressing the two together. 
     An alternate assembly is known where the water shield barrier is essentially a flat sheet bonded to resilient sound absorbing material such as nonwoven fiber pads, initially attached to the interior side of a trim panel, and then the entire assembly is mounted to the trim panel. This method depends on consistent thickness, density and compressive resiliency of the nonwoven fiber pad to exert the proper force to self-seal the water shield to the door sheet metal. 
     Care must be taken during the shipping of the water shield to the vehicle assembly plant. The adhesive must be protected from adjacent surfaces so that errant sticking to the wrong surfaces is prevented. Most materials have a side that has a release coating to which the adhesive will not stick and a bond side to which the adhesive is applied. These parts can then be stacked together on top of each other in a shipping container without the need for an additional release liner. A thin sheet of a release liner may also be used to cover the adhesive during shipping. The release liner is removed just prior to assembly of the water shield on the metal door inner panel. 
     There is a constant need to improve vehicle assembly efficiency. This has led to the trend toward modularity in which more and more vehicle components are assembled into sub-assemblies, which are then installed in a vehicle as a single component. Thus, it would be desirable to improve the assembly of a door water shield to the vehicle door in a manner that improves assembly efficiency, and reduces assembly time, labor and cost. 
     SUMMARY 
     The present invention is an apparatus and method for attaching a modular vehicle door water shield, premounted on an inner door trim panel assembly, to an inner door panel in a single step. The inventive apparatus is a particular shape of the water shield, a particular selection of resilient base sheet, and a particular selection of an adhesive or foam in place gasket that causes the modular water shield and the door trim panel to effectively seal water, wind, noise and dust when installed as a modular unit. 
     Specifically, the present invention is a vehicle door water shield apparatus, which is mountable on an inner door trim panel and joinable along with the inner door trim panel to the inner panel of a vehicle door. The door water shield includes a formed attachment surface integral with the overall water shield barrier, which is disposed in an interference position with the door inner panel when the inner door trim panel and the water shield are mounted on the inner panel of the vehicle door. A seal material, such as a pressure sensitive adhesive or a foamed in place gasket, is carried on the formed attachment surface for sealing of the water shield to the vehicle inner door panel. 
     The formed attachment surface is molded into a specially shaped section at or near the periphery of the water shield, which is deflectable under interference engagement with the door inner panel. The attachment surface can be a three-sided or inverted U shape deflectable surface within the periphery of the water shield and/or a cantilevered end on the periphery of the water shield. 
     In one aspect of the invention, the apparatus includes an inner door trim panel attachable to a vehicle inner door panel. A door water shield is attached to the inner door trim panel. An attachment surface is carried on the water shield and disposed in an interference position with a vehicle door inner panel when the inner door trim panel and the water shield are mounted on the door inner panel. A seal material is carried on the attachment surface for sealing attachment of the water shield to the door inner panel. 
     Another aspect of the invention is a method of manufacturing a vehicle door formed of joined inner and outer sheet metal panels and an inner trim panel mounted on the inner door sheet metal panel. The method includes the steps of: 
     forming the door water shield with an attachment surface disposed in interference position with the door inner panel when the door water shield and inner door trim panel module is attached to the door inner painted sheet panel; 
     applying a seal material on the attachment surface; 
     attaching the door water shield to the inner door trim panel to form a module; and 
     attaching the inner door trim panel and door water shield module to the door inner panel while simultaneously sealing the door water shield to the door inner panel through interference contact of the attachment surface of the door water shield with the door inner panel. 
     The present apparatus and method simplifies the assembly of vehicle doors by reducing assembly, labor time and associated cost due to the modular arrangement of the door water shield and inner door trim panel and the interference mounting of the adhesive on the attachment surface of the water shield on the door inner panel which automatically creates the pressing force necessary to securely seal the adhesive or gasket on the water shield to the door inner painted sheet metal panel at the same time the inner door trim panel itself is being attached to the door inner panel. This eliminates any separate mounting of the door water shield to the door inner panel as in previous vehicle door constructions. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The various features, advantages and other uses of the present invention become more apparent by referring to the following detailed description and drawing in which: 
     FIG. 1 is a cross sectional view of a vehicle door assembly incorporating a door water shield according to the present invention depicted in an assembled state; 
     FIG. 2 is a plan elevational view of another example of a door water shield according to the present invention; 
     FIG. 3 is a partial, enlarged perspective view of the door water shield shown in FIG. 2; 
     FIG. 4 is a cross sectional view showing the door water shield of FIGS. 2 and 3 in a static design pictorial representation of an assembled interference state; 
     FIG. 5 is a cross sectional view, similar to FIG. 4, but showing the door water shield in its actual deflected state; 
     FIG. 6 is a partial, perspective view of an alternate aspect of the door water shield of the present invention; 
     FIG. 7 is a partial, cross sectional view showing another design aspect of the door water shield according to the present invention; and 
     FIG. 8 is a partial, cross sectional view showing another aspect of the door weather shield according to the present invention; 
     FIG. 9 is a partial, cross sectional view showing another aspect of the door water shield according to the present invention; and 
     FIG. 10 is a perspective view of another aspect of the present invention. 
    
    
     DETAILED DESCRIPTION 
     Referring to FIG. 1, the typical construction of a vehicle door will be first be described by way of background to illustrate the advantageous use of the present invention. 
     A conventional vehicle door  10  includes an outer, typically sheet metal panel  12  which is joined at its peripheral edges to an inner, typically sheet metal panel  14 . Central upper portions of the outer and inner panels  12  and  14  are spaced apart to define an opening to a hollow interior cavity formed between the spaced outer and inner panels  12  and  14 . A glass window  16  is moveably mounted through the opening between the upper portions of the outer and inner panels  12  and  14  for movement into and out of the cavity between the outer and inner panels  12  and  14 . 
     Although not shown in FIG. 1, conventional window regulator and door lock and/or mirror control elements are also mounted in the door cavity and connected to at least the lower portion of the window  16  and to door lock and mirror mechanisms, not shown, to control movements of the window, door locks and mirror in response to interior actuators usually mounted through an inner door trim panel  18 . The inner door trim panel  18  is a three dimensional formed surface of various plastics, fabric or natural material combinations. The inner door trim panel  18  is mounted on the inner door panel  14  by means of hooks, fasteners or clips, not shown. 
     According to the present invention, a door water shield or barrier  20  shown in one aspect in FIG. 1, and in another aspect by reference number  22  in FIGS. 2-6, is mounted by means of friction fit, RF welding, clips, or other suitable fasteners, not shown, to the inner surface of the door inner trim panel  18 . The door water shield  20  is formed of suitable elastomeric, resilient materials, including various polyolefins, such as, but not limited to, polyethylene and polypropylene, which are foamed or not foamed. 
     The door water shield  20  or  22  can be a flat sheet or formed with pockets, recesses and/or even apertures to accommodate various hardware and actuators mounted externally and internally of the vehicle door  10 . 
     In addition, optional acoustic materials denoted by reference number  24  in FIG. 1 may be applied as a single sheet or in separate pieces to various portions of the door water shield  20  or  22 , typically between the water shield  20  and the door inner trim panel  18  or between the water shield  20  and vehicle door panel, to provide acoustic features to dampen sounds from entering the passenger compartment of the vehicle through the door  10 . 
     According to the present invention, the door water shield  20  or  22  is designed to be initially attached to the inner surface of the inner door trim panel  18  to create a single sub-assembly or module for unitary mounting of the resulting sub-assembly in a single step to the door inner panel  18 . 
     In order to create the desired sealing characteristics for the water shield  10  with respect to the door inner panel  14  to prevent the entry of air, dust and water into the vehicle passenger compartment, a seal is created between the entire periphery or at least a substantial portion of the entire periphery of the door water shield  20  or  22  and the door inner panel  14 . A seal material, such as an adhesive  26 , is employed to create the seal. The adhesive  26  may provide a permanent bond or, more typically, a pressure sensitive adhesive is employed to bond the water shield to the inner door panel  14 . The adhesive  26  is applied in a thin film or bead. Variations of beads, such as an extruded bead, swirl, spray or film coating or a foamed, nitrogen blown bead are also possible. 
     According to the present invention, the term “adhesive” will be understood to include any type of adhesive that provides the tack and bond strength regardless of the application method or adhesive configuration. Adhesive at the bonding surface will be understood to mean a material or treatment of a material that provides a seal when assembled, such as, but not limited to, cling foam and impregnated foams. 
     In the case of a foam in place gasket bead used as the seal material  26 , a one part or a two part, mixed, foamed in situ bead or gasket is applied to the door inner trim panel  18  to securely attach the water shield  20  to the trim panel  18 . At the same time, the foam in place gasket will allow removal and installation without damaging the water shield or creating bonding issues. 
     The use of a foam material as the seal material also makes use of the deflectable attachment surface as described herein to desirably minimize the attachment force levels necessary to securely seal the door water shield  20  to the vehicle door inner panel  14 . However, in this aspect, the mechanical fasteners used to mount the door inner trim panel  18  to the door inner panel  14  will provide the necessary mounting force required to maintain the foam material in a sealed, compressed state between the door water shield  20  and the door inner panel  14 . 
     As shown in FIG. 2 for the water shield  20 , a raised, deflectable attachment surface  30  is provided in a continuous or substantially continuous manner with none, one or multiple discontinuities generally about the peripheral extent of the inner surface of the water shield  20 . The outermost surface  32  of the raised surface  30  has a dimension or extent from the main plane of the water shield  22  so as to place the inner surface  32  and the adhesive bead  26  carried thereon in interference with a mating surface of the door inner panel  14 . 
     In aspect to the invention shown in FIGS. 2-5, the height of the raised surface  30  from the door inner trim panel  18  to the outermost surface  32  is greater than the distance or dimension between the door inner trim panel  18  and the inner surface of the door inner panel  14  when the inner door trim panel  18  is mounted in its nominal position on the door inner panel  14  as shown in FIG.  4 . This interference dimension shown by reference  34  creates a force against the rigidity of the raised surface  30  during the attachment of the door inner trim panel  18  to the door inner panel  14  which deforms the surface  30  to a sufficient extent to generate a force high enough to forcibly seal the seal material  26  on the raised surface  30  to the door inner panel  14  at the same time the door inner trim panel  18  is being affixed to the door inner sheet metal panel  14 . For the raised surface  30  which has a generally inverted U-shape with respect to the main extend of the water shield  22 , the deformation occurs in the side walls  38  and  40  and in the end surface or end wall  32  as shown in FIG.  5 . The deformation creates stresses in the raised surface  30 , which generates the required attachment force to automatically forcibly seal the seal material  26  to the door inner panel  14  without the need for separate application pressure from an installer, machine, etc. 
     When an adhesive is used as the seal material  26 , the deflection or deformation provides the required attachment force to forcibly adhere the adhesive material to the door inner panel  14  to effectively seal the door water shield  20  to the door inner panel  14 . In the case of foam in place gasket used as the seal gasket material  26 , the deformation or deflection provides the necessary force to effect a complete seal between the door water shield  20  and the door inner panel  14  by compression of the foam in place gasket. 
     Referring back to FIG. 2, it can be seen that the raised surface  30  extends continually above the periphery the door water shield  22 . Thus, in this example, the entire raised surface  30  is deformed in the manner shown in FIG. 5, when the door inner panel  18  is attached to the inner sheet metal panel  14 . 
     Other mounting arrangements are also possible. As shown in FIG. 6, certain vehicle door inner panels require a deep draw. Such a condition may provide little or no support for the water shield  22 . Thus, an additional rib or surface  44  is formed or mounted on the door inner trim panel  18  to support an edge of the door water shield  22 . In this construction, the raised surface  30  is cantilevered from the inner portion of the water shield  22  mounted generally in contact with or close proximity to the door inner trim panel  18 ′. However, the interference position of the end surface  32  of the raised surface  30  will still create sufficient force to forcibly seal the adhesive or gasket material  26  bead to the door inner panel  14  when the door inner trim panel  18 ′ is itself affixed to the door inner sheet metal panel  14 . 
     FIG. 7 depicts another aspect of a raised surface on a door water shield  50 . In this aspect, the raised surface  52  is in a form of a straight wall  54  connected to the main extent of the water shield  50  by a sidewall  56 . The seal material  26  is carried on a straight wall  54 . The length of a side wall  56  from the door inner trim panel  18  is selected to place the adhesive bead  26  in a straight wall  54  in an interference condition with the inner door panel  14 . This interference causes a deflection in the straight wall  54  as the door inner trim panel  18  is affixed to the door inner panel  14 . This deflection creates a sufficient force, which securely attaches and seals the adhesive or gasket material  26  and thereby the entire water shield  50  to the door inner panel  14 . 
     Referring back to FIG. 1, the raised surface may also take an S-shape  60 . Unlike the raised inverted U-shaped surface  30  shown in FIGS. 2-5 wherein the outer peripheral edge  31  of the water shield  22  is in contact with the door inner trim panel  18 , the entire S-shape surface  60  cantilevered or projects moveably outward from the door inner trim panel  18 . The S-shape has a restorative force after initial deflection. 
     It should be noted that FIG. 1 shows a combination of the inverted U-shaped raised section  30 , which extends around the top and two sides of the door inner trim panel  18 . The S-shaped surface  60  is generally provided along a deep draw area at the lower extent of the water shield  20 . The S-shaped surface  60  provides a consistent deflection force over a longer deflection curve. This allows flexibility in the amount of force exerted by the S-shape section on the seal material  26  due to a longer travel distance to securely attach the adhesive bead  26  to the door inner panel  14 . 
     As shown in FIG. 8, the raised surface may also be in the shape of a U-shaped section  64 , which terminates in a straight wall  66  carrying the seal material  26 . The U-shape section  64  on the water shield  20  provides a deflection force, which rises rapidly on a small deflection. The general stiffness of the water shield  20  would generate required force to securely seal the seal material  26  to the door inner panel  14 . 
     FIG. 9 depicts a combination of the U-shaped section  64  with the aspect to the invention shown in FIG. 8 having the S-shaped section  60  of FIG. 1 terminating in a straight wall section  70  carrying the seal material  26 . This provides the deflection characteristics of the S-shaped section  60  described above with the rapid rising deflection force on relatively small deflections of the U-shaped section  60  shown in FIG.  8 . 
     Yet another aspect of the present invention is shown in FIG. 10 in which a door water shield  80  is depicted as a formed sheet of resilient material. Although the door water shield  80  may take any form depending upon the shape and hardware requirements of a particular door application, in this aspect of the invention, the seal material attachment surface  82  is in the form of a raised sidewall integrally formed as part of the entire sheet. The attachment surface  82  is formed as part of the sheet and not as a planar edge having a raised attachment surface as in the previously described and illustrated aspects of the door water shield according to the present invention. Forming the attachment surface  82  as part of the actual sidewall formation of the door water shield  80  affords design flexibility as an attachment surface separate from the formed surfaces of the door water shield. 
     As in the previous aspects of the invention, a seal layer, typically in the form of a bead  84  is applied to the peripheral edge of the attachment surface  82  typically continuously about the entire periphery of the attachment surface  82 . It will be understood that discontinuities may also be formed in the attachment surface  82  and/or the seal material  84  is required to meet a particular application design. 
     Regardless, the attachment surface  82  will deflect under attachment pressure when the door water shield  80  is applied to the door inner panel  14  in the same manner as the aspects of the present invention described above. This deflection will generate a sufficient sealing force to firmly affix the sealing material  84  to the door inner panel  14 . 
     In conclusion, there has been disclosed a unique self-sealing door barrier or water shield which creates a seal between the barrier and the door inner sheet metal panel simultaneously with attachment of the door inner trim panel on which the water shield barrier is mounted to the door inner panel without the need for additional pressure application to the seal material on the barrier. The surface on the barrier carrying the seal material may be provided in different cross sections or cantilevered shapes to provide different deflection/force characteristics to suit the needs of many different applications. The self-sealing barrier simplifies the overall assembly of the vehicle door by eliminating the need for separate sealing attachment of the barrier to the door inner sheet metal panel.