Patent Publication Number: US-2022219519-A1

Title: Below Belt Seal Assembly, Associated Window Sealing System, And Method For Manufacturing Same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 63/136,293 filed Jan. 12, 2020, the disclosure of which is herein incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates, generally, below belt seal assemblies including a bracket for use in window sealing systems and associated window seal assemblies, and associated methods for manufacturing same. 
     BACKGROUND 
     Conventional seal assemblies are used in a number of different industries to provide a seal between different components which may be movable relative to one another. By way of non-limiting example, seal assemblies such as weatherstrips, weatherseals, glassrun moldings, window seals, and the like are used in the automotive industry to seal between a vehicle door defining a window opening, and a glass panel supported for sliding movement relative to the door to selectively close the window opening. These conventional seal assemblies may be operatively attached to different portions of the vehicle in a number of different ways, such as with fasteners, clips, and the like. 
     Those having ordinary skill in the art will appreciate that seal assemblies may be manufactured in a number of different ways to suit specific vehicle application requirements. To this end, conventional seal assemblies are formed from one or more extruded members which are molded together, such as with a plastic injection process, which bonds the extruded members together at a predetermined location corresponding to a portion of the vehicle, such as at a corner of the window opening, to form a molded seal assembly such as a below belt seal assembly. In order to facilitate attachment to the vehicle, various types of clips, locators, and/or brackets are often subsequently attached to the molded seal assembly at predetermined locations which correspond to fastening locations of the particular vehicle. To this end, holes or other formations may be defined in one or more of the extruded members prior to molding, and clips, fasteners, locators, and the like may be subsequently installed into the holes/formations after the molded seal assembly has been formed. 
     While these below belt seal assemblies and window seal assemblies as associated methods of manufacturing such seal assemblies known in the related art have generally performed well for their intended purpose, there remains a need in the art for improvements to the seal assemblies and their associated method of manufacture. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a window sealing system for a vehicle having a movable window that includes a below belt seal assembly. 
     The below belt seal assembly includes an extruded strip of material extending in length between a first strip end and a second strip end, the extruded strip of material having a base and first and second sides extending from the base and with each of the first and second sides having an engagement area, with a first lip extending outwardly from the engagement area of the first side and a second lip extending outwardly from the engagement area of the second side. The below belt seal assembly also includes a molding forming at least one bracket bonded to the extruded strip of material and extending outwardly from one of the sides. The below belt seal assembly also includes a fastener attached to the bracket for facilitating mounting of the below belt seal assembly to the vehicle. The window seal assembly also includes an upper glass run seal assembly having one or more additional extruded strips of material with a portion of said upper glass run seal assembly disposed adjacent the below belt seal assembly for accepting the moveable window disposed within the below belt seal assembly. 
     The present invention is also directed to an associated method of manufacturing the below belt seal assembly for use in the window sealing system. 
     In certain embodiments, the method of manufacturing a below belt seal assembly includes the use of a mold tool having a lower mold and an upper mold with a mandrel having domed region extending transversely from the lower mold, and the mold tool having a first slide tool and a second slide tool. The method includes the step of extruding a strip of material extending in length between a first strip end and a second strip end, the strip of material having a base and first and second sides and with each of the first and second sides having an engagement area, with a first lip extending outwardly from the engagement area of the first side and a second lip extending outwardly from the engagement area of the second side. The method also includes the steps of positioning the strip of material onto the mandrel; moving the first slide tool towards the mandrel from a first position to a second position with the first slide tool moving at an angle relative to the mandrel; abutting a portion of the first slide tool with the engagement area of the first side of the strip of material when the first slide tool is in the second position to stretch the first side of the strip of material against one side of the domed region of the mandrel; moving the second slide tool towards the mandrel from a first position to a second position with the second slide tool moving at an angle relative to the mandrel; abutting a portion of the second slide tool with the engagement area of the second side of the strip of material when the second slide tool is in the second position to stretch the second side of the strip of material against an opposing side of the domed region of the mandrel; moving the upper mold towards the mandrel from an open position to a closed position to form a molding cavity defined within the upper and lower molds, the mandrel, and the first and second slide tools in the second position; directing mold material into the molding cavity to form a molding over the length of the extruded strip of material and to form at least one bracket with the mold material bonding the formed bracket to the strip of material to form the below belt seal assembly; and attaching one or more fasteners to the at least one bracket for facilitating mounting of the below belt seal assembly to the vehicle. 
     In either method, the steps of moving the first and second slide tool can be performed by moving the first and second slide tools diagonally or laterally. Still further, in these methods, the fastener can be loaded onto a pin on one of the slide tools and molded into the bracket during the step in which the mold material is directed into the mold cavity. 
     The method of the present invention for manufacturing a below belt seal assembly including a bracket, offers advantages over prior manufacturing methods for making below belt seal assemblies. In particular, the method offers a simple manufacturing process that builds upon currently available molding and extrusion processes. Also, when the below belt seal assembly is included into a window sealing system and mounted within the body of a vehicle, the formed window seal system has a nearly zero tolerance between the below belt seal assembly with the bracket and the body of the vehicle. Further, in certain embodiments in which the fastener is molded into the bracket, the present invention eliminates the potential for a missing fastener. 
     Further, in certain embodiments, the window sealing system and associated window sealing assembly may only utilize one fastener per bracket in the below belt seal assembly, reducing complexity in a manufacturing setting. 
     In further embodiments, as noted above, the present invention is also directed the attachment of the below belt seal assembly with the bracket, and the associated window seal assembly, to the vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. 
         FIG. 1  is a partial side view of a door of an automotive passenger vehicle including a window seal assembly for a window contained within the door in accordance with an exemplary embodiment of the present invention with the window in a closed position. 
         FIG. 2  is a section side view of the door of  FIG. 1  with the window in an open position. 
         FIG. 3A  is a front side view of a system forming the window seal assembly of  FIGS. 1 and 2  according to one exemplary embodiment with the below belt seal assembly positioned adjacent to an upper glass run seal assembly and separated by a gap. 
         FIG. 3B  is a front side view a system forming the window seal assembly of  FIGS. 1 and 2  according to one exemplary embodiment with the below belt seal assembly secured to an upper glass run seal assembly via a molding. 
         FIG. 4  is a perspective view of the below belt seal assembly prior to incorporation into the window seal assembly of  FIGS. 1-3 . 
         FIG. 5  is a side section view of the below belt seal assembly of  FIG. 4  taken along line  5 - 5 . 
         FIG. 6A  is logic flow diagram of process for forming the below belt seal assembly according to an alternative configuration to the below belt seal assembly of  FIG. 4 . 
         FIG. 6B  is a logic flow diagram of the subsequent formation of the system and window seal assembly including the below belt seal assembly formed according to the process of  FIG. 6A . 
         FIGS. 7-10  are various schematic illustrations of the mold tool used to form the below belt seal assembly generally according to the method of  FIG. 6A . 
         FIG. 11  is a side view of the below belt seal assembly removed from the mold in  FIGS. 7-10  and including an additional fastener for subsequently attaching the below belt seal assembly to the vehicle. 
         FIG. 12  is a side view of the below belt seal assembly formed in the process of  FIG. 6A  and corresponding to the perspective view of the below belt seal assembly of  FIG. 4 . 
         FIG. 13  is a side view alternative below bracket seal assemblies of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, wherein like numerals indicate corresponding parts throughout the several views, a portion of an automotive passenger vehicle is shown at  30  in  FIGS. 1 and 2 . The vehicle  30  has a body, generally indicated at  32 , and a plurality of doors  34  (represented by a single door  34  in  FIGS. 1 and 2 ) coupled to the body  32 . In certain embodiments, such as shown in  FIG. 1 , the door  34  may be considered a portion of, or extension of, the body  32 . 
     Each of the doors  34  has a window frame  36  defining a window opening  37  that may include a window  38 , and a seal assembly  40  adjacent to the window frame  36 . In the representative embodiments illustrated herein and depicted throughout the drawings, the seal assembly  40  is realized as a window seal assembly  40  which is coupled to and extends along at least a portion of the window frame  36  and also supports the encapsulated glass window  38 . However, those having ordinary skill in the art will appreciate that the seal assembly  40  could be realized in a number of different ways, for different vehicle  30  applications or for different types of vehicles  30 , without departing from the scope of the present invention. Moreover, while the present invention is adapted for use with automotive passenger vehicles, it will be appreciated that the seal assembly  40  could be used in connection with any type of vehicle, such as heavy-duty trucks, trains, airplanes, ships, construction vehicles or equipment, military vehicles, or any other type of vehicle that utilizes seal assemblies  40 . 
     Referring to  FIGS. 3A and 3B , one embodiment of a window sealing system  45  is shown that includes a below belt seal assembly  70  and an upper glass run seal assembly  55  that, when positioned within the vehicle  30  such as shown in  FIGS. 1-2 , also can be defined or otherwise realized as the window seal assembly  40 . In certain embodiments, as will be described below, the upper glass run seal assembly  55  may include one or more extruded strips of material operatively attached to each other and to the below belt seal assembly  70 , as will be described further below. 
     In the embodiment illustrated in  FIGS. 1-2 , the upper glass run seal assembly  55  includes a first extruded strip  58  (i.e., a first strip of material  58 ) operatively attached to the below belt seal assembly  70 , a second extruded strip  60  (i.e., a second strip of material  60 ) operatively attached to the first extruded strip  58 , and a third extruded strip  62  (i.e., a third strip of material  62 ) operatively attached to the second extruded strip  60  to form the window sealing system  45  and window sealing assembly  40  as described in greater detail below. For ease of description the extruded strips of material  58 ,  60 ,  62  of the upper glass run seal assembly  55  may alternatively be referred to hereinafter as strips of material  58 ,  60 ,  62  or simply as strips  58 ,  60 ,  62 . In alternative embodiments, the upper glass run seal assembly  55  only requires at least one extruded strip of material that is coupled to the 
     In the representative embodiments illustrated herein, the extruded strips  58 ,  60 ,  62  each have a generally curved profile and are configured to seal against a window closure member  35 , including sealing against the window  38 , when the window closure member  35  is in the closed position (not shown in detail but generally shown in  FIGS. 1 and 2 , but generally known in the art). However, those having ordinary skill in the art will appreciate that the window seal assembly  40  could have any suitable profile, shape, or configuration sufficient to effect receiving the window closure member, including the window  38 , in the closed position without departing from the scope of the present invention. 
     In the illustrated embodiments, the first extruded strip  58  is operatively attached to both the second extruded strip  60  as well as to the glass window  38  via a molding  66  which bonds the extruded strips  58 ,  60  together. Specifically, the molding  66  of the window seal assembly  40  couples the first extruded strip  58  and the second extruded strip  60  together in a predetermined orientation that is complimentary to the shape and orientation of the window frame  36  of the vehicle  30 , as described in greater detail below. Similarly, the second extruded strip  60  is operatively attached to both the third extruded strip  62  as well as to the glass window  38  via a molding  68  which bonds the extruded strips  60 ,  62  together. Specifically, the molding  68  of the window seal assembly  40  couples the second extruded strip  60  and the third extruded strip  62  together in a predetermined orientation that is complimentary to the shape and orientation of the window frame  36  of the vehicle  30 . 
     In certain embodiments, the first extruded strip  58  has a generally U-shaped profile that extending between the strip ends  159 ,  161  defined by a base  163 , or body  163  and includes a first side  165  and a second side  166  (i.e., a first arm  165  and a second arm  165 ) spaced from one another and each extending transversely from the base  163 . Similarly, in certain embodiments, the second extruded strip  60  and third extruded strip  62  also have a generally U-shaped profile that extending between the respective strip ends  169 ,  171  and  179 ,  181  defined by a respective base  173 ,  183  (or body  173 ,  183 ) that each include a first side  175 ,  185  and a second side  176 ,  186  (i.e., a first arm  175 ,  185  and a second arm  176 ,  186 ) respectively spaced from one another and respectively extending transversely from a respective base  173 ,  183 . 
     The strips  58 ,  60 ,  62  are typically formed from a flexible and durable polymeric material that can create a seal to a component within the door  34 . By way of non-limiting example, one or more portions of the strips  58 ,  60 ,  62  of material could be manufactured via a plastic extrusion process utilizing one or more predetermined materials (and hence are referred to as extruded strips of material  58 ,  60 ,  62  as noted above), such as from one or more types of EPDM (Ethylene Propylene Diene Monomer) rubber and/or TPV (Thermoplastic Vulcanized) rubber. 
     In the illustrated embodiments, the body  163 ,  173 ,  183  of the strips  58 ,  60 ,  62  also supports a carrier (not shown) therein, which similarly has a generally U-shaped profile. The carrier may be manufactured from metal, such as steel, or from any other suitable material, and may have other profiles (e.g., rectangular), without departing from the scope of the present invention. 
     In certain embodiments, the body  163 ,  173 ,  183  of the first extruded strip  58 , second extruded strip  60 , and third extruded strip  62  are realized as a “division bar” and includes one or more sealing lips (similar to the sealing lips  81 ,  83  of the strip  72  of material of the below belt seal assembly  70  described below) which are each configured to engage portions of the window closure member  37  as the window closure member  37  and window  38  moves between open and closed positions with respect to the window frame  36 . 
     In addition to bonding the extruded strips  58 ,  60 ,  62  together, in the illustrated embodiments of the window seal assembly  40  depicted throughout the drawings, the moldings  66 ,  68  also at least partially encapsulates the glass window  38  and may bond to one or more locators (not shown) used to help position, align, or otherwise attach the window seal assembly  40  to the window frame  36  of the vehicle  30  in proximity to the window  38 , such as via spring clips (not shown) attached to the locators. The moldings  66 ,  68  may also bond to other components, such as a bulb strip employed to compress against vehicle  30  trim pieces (not shown, but generally known in the related art). However, those having ordinary skill in the art will appreciate that the window seal assembly  40  could comprise a number of different arrangements of components beyond those illustrated in  FIG. 3  and could be of different shapes and configurations to suit particular vehicle  30  applications and, thus, could employ additional strips and/or moldings without departing from the scope of the present invention. Furthermore, while the illustrated embodiments of the moldings  66 ,  68  partially encapsulating the glass window  38 , it will be appreciated that the upper glass run seal assembly  55  could be provided with moldings  66 ,  68  which bonds the first and second and third extruded strips  58 ,  60 ,  62  together without also bonding to other components. Other configurations are contemplated. 
     The window seal assembly  40  further includes a below belt seal assembly  70  that is operatively attached to the upper glass run seal assembly  55  and in particular to the first extruded strip  58 , and is configured to facilitate rigidly securing the window seal assembly  40  to the door  34  and/or the body  32  of the vehicle  30  at a position below the window opening  37  as shown in  FIGS. 1 and 2 . Here, it will be appreciated that the rigid securing of the window seal assembly  40  via the below belt seal assembly  70  affords advantages in applications where the window seal assembly  40  is relatively large and/or heavy (e.g., supports the window  38  and window closure member  35 ), or in applications where additional retention rigidity is required beyond the retention afforded by locators and spring clips. 
     The below belt seal assembly  70 , as shown in  FIGS. 1-5, 8-12 and 14-15  and as best shown in  FIG. 4 , includes an extruded strip of material  72  having a generally U-shaped profile and including an intermediate portion  74  extending between a first strip end  76  and a second strip end  78 . The extruded strip  72  of material (see  FIG. 14 ), similar to the extruded strips  58 ,  60 ,  62 , is typically formed from a flexible and durable polymeric material that can create a seal to a component within the door  34 . By way of non-limiting example, one or more portions of the strip of material  72  could be manufactured via a plastic extrusion process utilizing one or more predetermined materials, such as from one or more types of EPDM rubber and/or TPV rubber, and hence is referred to as an extruded strip of material  72 , and extruded strip  72 , or strip  72  hereinafter. 
     Also similar to the first, second and third strips  58 ,  60 ,  62 , the extruded strip of material  72  includes a first side  73  and a second side  75  each extending transversely from a base  85 , and in certain embodiments with each side  73 ,  75  extending along the entire length of the strip of material  72  between the first and second strip end  76 ,  78  (including along the intermediate portion  74 ), and with the interior surfaces of the sides  73 ,  75  and base  85  defining an internal channel  87  that is configured to receive, and in partially encapsulate and seal, to an outer portion of the window  38  when the window  38  is moved (i.e., lowered) within the door  34  during certain operations of the vehicle  30 . In addition, each of the first and second sides  73 ,  75  include an engagement area  73 A,  75 A. 
     In certain of these embodiments, a terminal end of each the first and second sides  73 ,  75 , opposite the base section  85  and adjacent to and extending from the respective engagement area  73 A,  75 A, form an outward lip  77 ,  79  (see  FIG. 9 ). The outward lips  77 ,  79 , may extend along all or a portion of the first and second sides  73 ,  75  between the first and second strip ends  76 ,  78  (including along the intermediate portion  74 ). In certain embodiments, the outward lips  77 ,  79  extend transverse and outwardly from the length of the sides  73 ,  75 , and in further embodiments the outward lips  77 ,  79  are curved and extend transverse and outwardly to the length of the first and second sides  73 ,  75  at the terminal ends adjacent to and extending from the engagement areas  73 A,  75 A. 
     In still further embodiments, as also shown in  FIGS. 5 and 8-12 , the extruded strip of material  72  also includes an additional pair of sealing lips  81 ,  83  (sometimes alternatively referred to as finger like-projection portions  81 ,  83 ) extending respectively inwardly (and in a direction opposite the respective outward lips  77 ,  79 ) from one of the first and second sides  73 ,  75  at one or both of the respective first and second strip end  76 ,  78 . These sealing lips  81 ,  83  of the strip of material  72  abut or otherwise engage portions of the window  38  of the vehicle  30  when the window  38  is moved to the lowered position within the door  34  or other portion of the body  32  when the window seal assembly  40  is coupled within the vehicle  30  and when the window  38  extends within the internal channel  87  towards the inner surface of the base section  85  when the window  38  is moved to the lowered position within the door  34  or other portion of the body  32 . 
     In certain embodiments, the base  85 , sides  73 ,  75  and lips  77 ,  79  are formed of a common polymeric material, such as the one or more types of EPDM rubber and/or TPV rubber as described above. 
     The below belt seal assembly  70  also includes one or more fasteners  80  that are respectively coupled, and preferably bonded, to the intermediate portion  74  and/or to one or both of the first and second strip ends  76 ,  78  via a molding  82  that forms at least one bracket  193 , such as a plurality of brackets  193 , that includes the afore-mentioned fasteners  80 . In certain embodiments, and as illustrated in  FIGS. 3, 5, 6, 9-13, 15 and 16  herein, the fastener  80  is in the form of a threaded nut  80 . 
     In the embodiment shown, the molding  82  is bonded to the base  85  of the strip of material  72  along the entirety of the length between the first and second strip ends  76 ,  78  including along the intermediate portion  74 , although in other embodiments the molding  82  may be bonded to either one of the first or second sides  73 ,  75  (alone or in combination with being bonded to the base section  85 ) along the entirety of the length between the first and second strip ends  76 ,  78  including along the intermediate portion  74 . In still further embodiments, the molding  82  is bonded to the extruded strip of material  72  (along the base section  85  and/or along one or both of the first or second sides  73 ,  75 ) along less than the entirety of the length between the first and second strip ends  76 ,  78  including along the intermediate portion  74 . In these embodiments, the first and second lips  77 ,  79  each extend outwardly from the sides  73 ,  75  at a distance at least equal to the thickness of the molding  82  disposed on the sides  73 ,  75 . 
     In these embodiments, the molding  82  includes the at least one bracket  193  that are each operatively attached to the each of the fastener  80  and to the strip of material  72  such as via a molding process (by way of non-limiting example, via injection molding) with the molding  82  formed from a thermoplastic material such as Polypropylene (PP) or High-Density Polyethylene (HD-PE). 
     In certain embodiments that include the outward lips  77 ,  79 , such as shown in  FIG. 2 , the terminal ends  82 A,  82 B of the molding  82  partially surrounding the base section  85  and sides  73 ,  75  terminate at the respective engagement areas  73 A,  75 A and are thus spaced from the outward lips  77 ,  79  lips so as to provide a gap  93  between the terminal ends  82 A,  82 B of the molding  82  and the respective outward lip  77 ,  79 . 
     The fasteners  80  can be in the form of a threaded nut  80  as described above (see in particular  FIG. 5 ), or alternatively may take on other forms such as a threaded bolt. In certain embodiments such as when the fastener  80  is in the form of a threaded nut  80 , the fasteners  80  define access openings (access opening is shown in  FIG. 5  by arrow  190 ) for introduction of an additional fastening device  205  therethrough that cooperate with the fasteners  80  (i.e., engages with the fastener  80 ) to secure the window seal assembly  40  within the door  34  or within other portions of the body  32  of the vehicle  30 . By way of example, where the additional fastening device is a threaded bolt  205  such as shown in  FIG. 11 , and wherein the fastening device is a threaded nut  80  as also shown in  FIG. 11 , the threaded bolt  205  may be introduced through the access opening  190  of the threaded nut  80 , while being threadingly engaged to the threaded nut  80  within the access opening  190 , and with a portion of the bolt  205  extending within the body  32  (or door  34 ) of the vehicle  30  (such as being threadingly engaged with an opening in the body  32 ) to secure the below belt seal assembly  70  (and hence the window seal assembly  40  including the below belt seal assembly  70 ) to the body  32  (or door  34 ) of the vehicle  30 . 
     Even still further, other additional fasteners or fastening devices (not shown) that are not threaded may be utilized in conjunction with the fasteners  80  described herein in further alternative embodiments, including for example spring clips or u-nuts or other additional fastening devices having hook-like features (not shown) that are bonded to the intermediate portion  74  and function for securing the window seal assembly  40  to the door  34  or the body  32  of the vehicle  30 . 
     In the representative embodiments depicted herein, the below belt seal assembly  70 , is formed in-place such as via a molding process (by way of non-limiting example, via injection molding) from a thermoplastic such as Polypropylene (PP) or High-Density Polyethylene (HD-PE) within a mold (shown schematically in  FIGS. 7-10 ) according to the logic illustrated in  FIG. 6A  and as described below. Once formed, the below belt seal assembly  70  may be coupled with the one or more of the three extruded strips  58 ,  60  and  62  that individual or collectively define the upper glass run seal assembly  55  to form the window seal assembly  40 . 
     In certain embodiments, the below belt sealing system  70  may be subsequently positioned adjacent to the first extruded strip  58  of the upper glass run seal assembly  55 , such as shown in  FIGS. 3A and 3B . As shown in  FIG. 3A , the below belt sealing system  70  is positioned adjacent to the first extruded strip  58  with a small gap  47  present between the first strip end  76  of the extruded strip  72  and the strip end  159  of the first extruded strip  58  to form the window sealing system  45 . In certain other embodiments as shown in  FIG. 3B , the below belt seal assembly  70  may abut and/or may be subsequently bonded to the first extruded strip  58  of the upper glass run seal assembly  55 . The bonding could be accomplished through an additional molding  90  in an additional or concurrent molding process. Those having ordinary skill in the art will appreciate that the below belt seal assembly  70  could be formed from any suitable material sufficient to align, abut, or bond to the first extruded strip  58  and to facilitate proper alignment of the window seal assembly  40 . As yet another alternative, an adhesive (not shown) may be applied between the first strip end  76  and the strip end  159  of the first extruded strip  58 , without departing from the scope of the present invention. 
     In the embodiment illustrated in  FIGS. 1-2  and in  FIG. 3B , the three strips  58 ,  60  and  62  are illustrated and are coupled together and form the upper glass run seal assembly  55  that are secured together and to the below belt seal assembly  70  via the moldings  66 ,  68  and  90  as described above. However, in other embodiments, the window seal assembly  40 , in accordance with the present invention, can include the below belt seal assembly  70  coupled to the first extruded strip  58  with or without the additional extruded strips  60 ,  62  (i.e., the upper glass run seal assembly  55  can include the first extruded strip  58  alone or in combination with one or both of the additional strips  60 ,  62 ). Still further, in additional embodiments, the number of additional extruded strips can be more than the two additional extruded strips  60 ,  62  as shown. 
     Even still further, while the present invention as illustrated in  FIGS. 1-5  includes a first extruded strip  58  coupled to the first strip end  76  of the extruded strip of material  72  via the molding  90 , alternative embodiments are contemplated. 
     By way of non-limiting examples (not shown), an additional strip of extruded material similar to the first extruded strip  58  may also be coupled to the second strip end  78  of the extruded strip of material  72  via an additional molding similar to the molding  90 . Still further, the additional strip of extruded material may alternatively be coupled to the intermediate portion  74  of the extruded strip of material  72  via an additional molding similar to the molding  90 . Even still further, an additional extruded strip of material similar to the first extruded strip  58  may also be coupled to the second strip end  78  of the extruded strip of material  72  and a second additional strip of material may be coupled to the intermediate portion  74  of the extruded strip of material  72  via an additional molding or moldings similar to the molding  90 . 
     A molding method for forming the below belt seal assembly  70  similar to the embodiment illustrated in  FIG. 4  (and as shown in  FIG. 11 ), and the subsequent method for forming a window seal assembly  40  including the below belt seal assembly  70  and the upper glass run seal assembly  55  of  FIGS. 1-2  is depicted generically in  FIGS. 7-10  and in an accompanying logic flow diagram  200  in  FIGS. 6A and 6B  in accordance with one exemplary method of the present invention. 
     Referring first to  FIG. 6A  and to step  202 , the method  200  begins by providing a mold tool. The mold tool, shown in  FIGS. 7-10  by reference numeral  500  and illustrated schematically and not intended to provide precise dimensions or configurations corresponding to the formed below belt seal assembly  70  of the present invention, includes a mandrel  502 , an upper slide  504 , and a pair of slide tools  506 ,  508  with a first one  506  of the pair of slide tools including a pin  510 . The pin  510  may be coupled to or be integrally formed and project outward from the first one  506  of the slide tools. The mandrel  502  has a base region  511  and domed region  512  extending transversely from the base region  511 . The base region  511  includes a trough region  513  defining a cavity  515  positioned adjacent to the domed region  512 . In certain embodiments, the domed region  512  includes a top side  514  with a first side  516  and an opposing second side  518  extending from the top side  514 . The sides  516 ,  518  of the domed region  512  may each include a pocket region  523  for receipt of the sealing lips  81 ,  83 . In alternative embodiments, the pin  510  could alternatively be coupled to be integrally formed and project outwardly from the upper slide tool  504  and work in the same manner as the pin  510  coupled to or integrally formed with the first one  506  of the slide tools as shown in  FIGS. 7-10 . The method continues in step  204  by positioning the first slide tool  506  in spaced relationship from the first side  516  of the mandrel  502  and positioning a second slide tool  508  in spaced relationship to the second side  518  of the mandrel  502 . 
     Next, in step  206  and as best shown in  FIG. 7 , a strip of material  72  (i.e., the extruded strip of material  72  previously formed by the plastic extrusion process) having an intermediate portion  74  extending between a first and second strip end  76 ,  78  is loaded onto the mandrel  502  with the first strip end  76  positioned between the first side  516  of the domed region  512  of the mandrel  502  and the first slide tool  506  and with the second strip end  78  positioned between the second side  518  of the domed region  512  of the mandrel  502  and the second slide end  508  with the intermediate portion  74  positioned adjacent the top side  514  of the domed region  512  of the mandrel  502 . In alternative embodiments, step  206  can proceed prior to, or simultaneous with, step  204 . 
     In certain embodiments the ends of the sides  73 ,  75  of the strip of material  72  opposite the base  85  extend into cavity  515  defined by the trough region  513 . Further, in certain of these embodiments that include the outward lips  77 ,  79 , a terminal end or the entirety of each the outward lips  77 ,  79  is positioned within the cavity  515  defined by the troughed region  513 . 
     As noted above, as also shown in  FIGS. 7-10 , the strip of material  72  also includes the additional pair of sealing lips  81 ,  83  extending respectively inwardly from one of the first and second sides  73 ,  75  at one or both of the respective first and second strip end  76 ,  78  and these are positioned within the respective pocket region  523  along the sides  516 ,  518  of the domed region  512 . 
     Next, in step  208 , each of the pair of slide tools  506 ,  508  is moved (i.e., slid) towards the mandrel  502 , such as towards the domed region  512  of the mandrel  502 , from a first position to a second position to stretch the strip of material  72  against the mandrel  502 , such as against the domed region  512  of the mandrel  502 . This sliding of the pair of slide tools  506 ,  508  can be done simultaneously or sequentially (in either order). 
     In certain embodiments, the pair of slide tools  506 ,  508  are slid diagonally (shown by arrows  525 ,  530  in  FIG. 8 ) towards the mandrel  502  from the first position to the second position. 
     In certain embodiments, during this diagonal movement, a projection  517 ,  519  of the respective pair of slide tools  506 ,  508  covers a portion of the first and second sides  73 ,  75  within the cavity  515  adjacent to the troughed portion  513 , and in particular is brought into contact with the engagement area  73 A,  75 A of the first and second sides  73 ,  75  of the strip of material  72  and stretches the first and second sides  73 ,  75  along the respective opposing first and second sides  516 ,  518 . In embodiments including the outward lips  77 ,  79 , such as shown in  FIG. 9 , a projection  517 ,  519  of the respective pair of slide tools  506 ,  508  are brought into contact with the engagement area  73 A,  75 A of the first and second sides  73 ,  75  at a position adjacent to the respective outward lips  77 ,  79 . 
     Alternatively, as also shown in  FIG. 8 , the pair of slide tools  506 ,  508  are slid laterally (shown by arrows  526 ,  531  in  FIG. 9 ) towards the mandrel  502  from the first position to the second position by essentially the same method as described above. 
     Next, in step  210  in certain embodiments, the fastener  80 , such as a threaded nut  80 , is loaded onto the pin  510  of the first slide tool  506  (see  FIG. 8 ) with the access opening  190  defined the threaded nut  80  surrounding and in close proximity or in contact with the outer surface of the side of the pin  510 . In certain of these embodiments, step  210  can occur prior to or simultaneous with step  206  or  208 . 
     The location of the pin  510  along the first one  506  of the slide tools is illustrated schematically in  FIGS. 7-10 , is illustrated for ease of illustration in an alternative location from a pin  510  that would be used to form the below belt seal assembly  70  of  FIG. 4 . In particular, the location of the pin  510  in  FIGS. 7-10  forms the below belt seal assembly  70  as illustrated in  FIG. 11  having the access opening  190  extending in a direction ninety degrees offset from the corresponding access opening  190  in the below belt seal assembly  70  illustrated in  FIG. 4 . Still further, in alternatives to the illustration of  FIGS. 7-10 , the pin  510  could alternatively be coupled to or extend from the upper slide tool  504  or be positioned in alternative locations on the first one of the slide tools, and work in the same manner as the pin  510  coupled to or extending from the first one  506  of the slide tools as shown in  FIGS. 7-10 . 
     As noted above, the fastener  80  described in step  210  may take on alternative forms, including that of another threaded fastener such as a threaded bolt or a non-threaded fastener including but not limited to a spring clip, u-nut or a fastener having a hook-like feature. In these embodiments, the use of the pin  510 , and the loading of the fastener  510  onto the pin  510 , are not necessary. In addition, is still further alternative embodiments, the fastener  80  can be coupled to the formed one or more brackets  193  after formation of the below belt seal assembly  70 . 
     In step  212 , the upper slide  504  is slid towards the mandrel  502 , and in particular towards a top side  514  of the domed region  512  of the mandrel  502 , from an open position to a closed position, as shown by arrow  537  in  FIG. 8 , wherein the upper slide  504 , the pair of slide tools  506 ,  508 , the projections  517 ,  519  and the mandrel  502  define a molding cavity  520  therebetween when the pair of slide tools  506 ,  508  are in the first position and when the upper slide  504  is in the closed position. During step  212 , the fastener  80  and the strip of material  72  are contained in the molding cavity  520 . In certain embodiments, step  210  can occur prior to or simultaneous with step  208  or  210 . 
     In step  214 , and as also represented in  FIG. 8 , a molding material  522  is directed into the molding cavity  520  to form a molding  82  that bonds the fastener  80  to the extruded strip of material  72  to form the below belt seal assembly  70 . During this step, one or more brackets  193  are formed within the molding material  522  that include the fasteners  80  or serve as the location for the subsequent attachment of the fasteners  80 . 
     In step  216 , the upper slide  504  is retracted to the open position (shown by arrow  547  in  FIG. 9  or  FIG. 10 ) and the pair of slide tools  506 ,  508  are retracted from the second position back to the first position, thereby allowing the formed below belt seal assembly  70  to be removed from the mandrel (see  FIG. 11  in which the below belt seal assembly  70  is removed). Optionally, the sealing lips  81 ,  83  may be removed from the formed below belt seal assembly  70  as a part of step  214 . 
     In certain embodiments, as shown in  FIG. 9 , the pair of slide tools  506 ,  508  are slid diagonally (shown by arrows  535 ,  540 ) away from the mandrel  502  from the second position to the first position. The diagonal sliding of  FIG. 9  corresponds to the embodiment also illustrated in  FIG. 8  described above wherein the pair of slide tools  506 ,  508  are slid diagonally towards from the mandrel  502  illustrated by arrows  525 ,  530  and corresponding to Step  208 . 
     Alternatively, as shown in  FIG. 10 , the pair of slide tools  506 ,  508  are slid laterally (shown by arrows  545 ,  550 ) away from the mandrel  502  from the second position to the first position. The lateral sliding of  FIG. 10  corresponds to the embodiment also illustrated in  FIG. 9  described above wherein the pair of slide tools  506 ,  508  are slid laterally towards from the mandrel  502  as shown by arrows  526 ,  531  and corresponding to Step  208 . 
     In certain embodiments, during this diagonal or lateral movement shown by arrows  535 ,  540  or  545 ,  550 , the projection  517 ,  519  of the respective pair of slide tools  506 ,  508  uncovers the sides  73 ,  75  (and is disengaged from the engagement area  73 A,  75 A) within the cavity  515  adjacent to the troughed portion  513  and is brought out of contact with of the strip of material  72  corresponding to the sides  73 ,  75 . In embodiments that include the outward lips  77 ,  79 , this diagonal or lateral movement also uncovers a top portion of the outward lips  77 ,  79  adjacent to, and extending from, the sides  73 ,  75  to expose the gap  93  created between the terminal ends  82 A,  82 A of the molding  82  and the top surface of the outward lips  77 ,  79 . 
     In further embodiments, in addition to forming the below belt seal assembly  70 , such as also shown in the logic flow diagram of  FIG. 6A , the method continues as shown in  FIG. 6B  to form the window seal assembly  40  and associated window sealing system  45  including the below belt seal assembly  70 , the first extruded strip  58 , and optionally the second extruded strip  60  and third extruded strip  62  and any further additional strips that define the upper glass run seal assembly  55 . For ease of description, the method is described with respect to forming a window seal assembly  40  in  FIG. 6B  has only the first extruded strip  58  coupled to the below belt seal assembly  70  in steps  224  and  226  below, although in further embodiments additional strips such as the second extruded strip  60  and third extruded strip  62  can also be coupled to the first extruded strip  60  opposite the below belt seal assembly  70  with additional conventional steps extending from the non-conventional steps  224  and  226  of the present invention described below to form the window seal assembly  40  such as shown in  FIGS. 1-3 . 
     Referring now to  FIG. 6B  and in step  218 , a separate molding apparatus (i.e., separate mold from the mold  500 ) is provided having a one or more receptacles defining a molding cavity. 
     In step  220 , the below belt seal assembly  70  is positioned into the molding cavity of the separate mold within one of the one or more receptables  725 ,  730  contained in the molding cavity. 
     In step  222 , the first extruded strip  58  and optionally any additional strips of material (i.e., the second extruded strip  60  and/or the third extruded strip  62  in the embodiment shown in  FIGS. 1-3 ), depending upon the size and shape of the desired seal assembly  40 , are formed as the upper glass run seal assembly  55  in a prior step in a conventional forming process such as via extrusion process. The strips  58 ,  60 ,  62  may be formed from a flexible polymeric material that is capable of forming a seal with the window  38 . In certain embodiments, the flexible polymeric material is the same or a different material as the strip  72  used in the below belt seal assembly  70  as described above. By way of non-limiting example, one or more portions of the first extruded strip  58  and/or the second extruded strip  60  and/or the third extruded strip  62  could be manufactured via a plastic extrusion process utilizing one or more predetermined materials, such as from one or more types of EPDM rubber and/or TPV rubber as described above, and many include the carriers as described above. As opposed to forming the first extruded strip  58  and optionally any additional strips of material in step  222 , the first extruded strip  58  and optionally any additional strips of material (i.e., the second extruded strip  60  and/or the third extruded strip  62 ) may simply be provided in alternative embodiments of the method  200  as the upper glass run seal assembly  55 . 
     Next, in step  224 , one of the strip ends  169  of the first extruded strip  58  into the molding cavity within a second one of the one or more receptacles in the separate molding apparatus with a portion of the base section or body  163  of the first extruded strip  58  engaging the below belt seal assembly  70  in the first receptacle. In particular, corresponding to the embodiment of  FIGS. 1-3 , with the strip end  169  of the first extruded strip  58  engaging the first strip end  76  of the below belt seal assembly  70 . 
     Further, and optionally as a part of step  224 , the second extruded strip  60  and/or third strip are loaded into additional receptacles with the second extruded strip  60  engaging the first extruded strip  58  as described above and with the third extruded strip  62  engaging the second extruded strip  60  (and in particular the strip end  171  of the second extruded strip  60  engaging the strip end  179  of the third extruded strip  62 ). 
     In step  226 , material is directed into the molding cavity within the first one of the one or more receptacles of the separate mold to form a molding  90  bonding the first extruded strip  58  together with the below belt seal assembly  70  to form the window seal assembly  40 . 
     The window seal assembly  40 , and associated window seal system  45 , formed in accordance with this method that includes a threaded nut  80  as the fastener  80  and the threaded bolt  205 , may be then be introduced into the body  32  or door  34  of the vehicle  30  and secured to the body  32  or door of the vehicle  30  by threadingly engaging the bolt  205  within the access opening  190  of the threaded nut and engaging an end portion of the bolt  205  to the body  32  or door  34  to form the window sealing system  40  as described above. 
     In an alternative method to form the window seal assembly  40  of  FIG. 3A  from the window sealing system  45  including the below belt seal assembly  70  and upper glass run seal assembly  55 , the method merely consists of positioning the strip end  159  of the first extruded strip  58  of material of the upper glass run seal assembly  55  adjacent to, and in certain embodiments is adjacent and spaced from the first strip end  76  of the extruded strip  72  of material of the below belt seal assembly  70  to form a gap  47 . In certain embodiments, an adhesive can be applied to one or both of the strip ends  159 ,  76  to secure the first strip  58  to the strip  72  of the below belt seal assembly  70 , while in other embodiments a fastener can alternatively be used alone or in conjunction with the adhesive to secure the first strip  58  to the strip  72  of the below belt seal assembly  70 . 
     In alternative embodiments, as shown in  FIG. 13 , alternative below belt seal assemblies  70  are provided in which the number, or location, of the bracket  193  and fasteners  80  may be different from the embodiments illustrated in  FIGS. 4 and 11 . In particular, a single bracket  193  and fastener  80  is illustrated on two below belt seal assemblies  70  in  FIG. 13 , as compared to the below belt seal assemblies  70  of  FIGS. 4 and 11  that include two brackets  193  each having a single respective fastener  80 . 
     In still further embodiments, the fastener  80  may be coupled to bracket  193  in accordance with the embodiments of  FIGS. 4, 11 and 13  at any point and time during the assembly of the window seal assembly  40 , including in a post-production step to the steps described above. Preferably, the fastener  80  is bonded or otherwise secured or fastened to bracket  193  in this post-production step prior to the window seal assembly  40  being installed into door  34  and/or the body  32  of the vehicle  30  as described above. 
     While the invention has been described with reference to the examples above, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all examples falling within the scope of the appended claims.