Patent Publication Number: US-2021188054-A1

Title: Glazing assembly and forming method

Description:
TECHNICAL FIELD 
     The present disclosure relates to a glazing assembly and forming method. Aspects of the invention relate to a glazing assembly, an encapsulated assembly, a method of forming a glazing assembly, and a method of forming an encapsulated assembly. 
     BACKGROUND 
     It is known to provide a vehicle with a finisher component to form part of an exterior surface thereof. In certain designs, the finisher component may be located alongside a glazing panel. 
     The finisher component and the glazing panel are typically fitted as separate components. The glazing panel may be fitted to a body of the vehicle, for example using an adhesive and/or a mechanical fastener. The finisher component may then be fitted alongside the glazing panel. The finisher component may be fastened to the vehicle body using mechanical fasteners, such as blind clips. The resulting joint between the glazing panel and the finisher component is visible and there is typically a slight step/offset between the glazing panel and the finisher component. 
     A perspective view of a known glazing assembly  101  on a vehicle  102  is shown in  FIG. 6  by way of example. The glazing assembly  101  comprises multiple pieces which are fitted to the vehicle  102  as separate components. In particular, the glazing assembly  101  comprises a glazing element  110  and a finisher component  111 . A join line J 2  formed between the glazing element  110  and the finisher component  111  is represented by dashed lines in  FIG. 4 . 
     It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. 
     SUMMARY OF THE INVENTION 
     Aspects and embodiments of the invention provide a glazing assembly, an encapsulated assembly and a method of forming a glazing assembly as claimed in the appended claims 
     According to an aspect of the present invention there is provided a glazing assembly for a vehicle, the glazing assembly comprising:
         a glazing element having an inner surface and an outer surface, wherein a portion of the glazing element inner surface forms a first encapsulation area; and   a finisher component having an inner surface and an outer surface, wherein a portion of the finisher component inner surface forms a second encapsulation area;   the finisher component being connected to the glazing element by a connector composed of an encapsulation material which encapsulates the first encapsulation area and the second encapsulation area such that the glazing assembly comprises a substantially continuous outer surface. The encapsulation material bonds to the first encapsulation area and to the second encapsulation area, thereby fixedly connecting the glazing element and the finisher component. The glazing assembly is pre-assembled for installation on the vehicle. The glazing element outer surface and the finisher component outer surface form an outer surface of the vehicle.       

     The glazing assembly outer surface is at least substantially continuous. Thus, at least in certain embodiments, the glazing assembly outer surface is at least substantially free from discontinuities or interruptions, such as a step change in profile. The resulting glazing assembly may comprise a seamless joint between the glazing element and the finisher component. 
     The glazing assembly outer surface may be planar. Alternatively, the glazing assembly outer surface may be curved. For example, the glazing assembly outer surface may be curved in one or more direction. 
     At least in certain embodiments, the connector forms a water-tight seal between the glazing element and the finisher component. 
     The first encapsulation area is formed on the glazing element inner surface. At least in certain embodiments, the connector does not extend over the glazing element outer surface. Alternatively, or in addition, the connector does not extend over the finisher component outer surface. 
     The finisher component may comprise a stabilising member. The stabilising member may extend from the finisher component inner surface and form at least a portion of the second encapsulation area. 
     The stabilising member may be spaced apart from the glazing element inner surface. At least a portion of the connector may be disposed between the stabilising member and the glazing element inner surface. 
     The stabilising member may extend substantially parallel to the glazing element inner surface. The stabilising member may comprise a central longitudinal axis which extends substantially parallel to the glazing element inner surface which forms the first encapsulation area. 
     The second encapsulation area may be formed on two opposing sides of the stabilising member. 
     The glazing element could comprise interlocking means for interlocking with the connector. The interlocking means may comprise one or more of the following: an aperture, a channel, a recess and a protuberance. The interlocking means may be formed in the first encapsulation area. 
     The stabilising member may comprise interlocking means for interlocking with the connector. The interlocking means may comprise one or more of the following: an aperture, a channel, a recess and a protuberance. The interlocking means may be formed in the second encapsulation area. Alternatively, or in addition, the stabilising member may comprise a (negative) taper angle for interlocking with the connector. 
     The connector may form a joint between the glazing element and the finisher component. The joint may have an outer surface which forms a continuation of the glazing element outer surface and the finisher component outer surface. The join outer surface may be planar or curved. 
     The connector may comprise an elongate section disposed between the glazing element and the finisher component. The elongate section may comprise an outer surface which is profiled to form a continuation of at least one of the glazing element outer surface and the finisher component outer surface. The elongate section outer surface may, for example, comprise a convex curve or a planar surface. The elongate section outer surface may be moulded to form a continuation of at least one of the glazing element outer surface and the finisher component outer surface. 
     The glazing element and the finisher component may abut against each other. Alternatively, the glazing element and the finisher component may be spaced apart from each other. 
     The encapsulation material may be substantially rigid or inflexible. Alternatively, the encapsulation material may resiliently deformable to enable relative movement of the glazing element and the finisher component. The encapsulation material may, for example, comprise or consist of an elastomer. The encapsulation material may enable limited relative movement of the glazing element and the finisher component. 
     According to a further aspect of the present invention there is provided a vehicle comprising a glazing assembly as described herein. 
     According to a further aspect of the present invention there is provided an encapsulated assembly for an exterior of a vehicle, the encapsulated assembly comprising:
         a first component having a first inner surface and a first outer surface, wherein a portion of the first inner surface forms a first encapsulation area; and   a second component having a second inner surface and a second outer surface, wherein a portion of the second inner surface forms a second encapsulation area;   the first component and the second component being connected to each other by a connector, the connector being composed of an encapsulation material which encapsulates the first encapsulation area and the second encapsulation area such that the encapsulated assembly comprises a substantially continuous outer surface;   wherein the second component comprises a stabilising member forming the second encapsulation area. The stabilising member may extend from the second inner surface.       

     The first component and the second component may be formed from different materials. The first component may be formed of metal. The first component may be formed of a plastics material. 
     According to a further aspect of the present invention there is provided a method of forming a glazing assembly for a vehicle, the glazing assembly comprising a glazing element having an inner surface and an outer surface; and a finisher component having an inner surface and an outer surface; the method comprising:
         locating the glazing element and the finisher component in a mould;   introducing an encapsulation material into the mould to form a connector to connect the finisher component to the glazing element, the encapsulation material encapsulating a first encapsulation area formed on the glazing element inner surface and a second encapsulation area formed on the finisher component inner surface such that the glazing assembly comprises a substantially continuous outer surface. At least in certain embodiments, the mould may define the outer surface of the connector. Thus, the mould may be profiled to form the substantially continuous outer surface of the glazing assembly.       

     The finisher component may comprise a stabilising member extending from the finisher component inner surface. The method may comprise introducing the encapsulation material into the mould to encapsulate at least a portion of the stabilising member. 
     The stabilising member may be spaced apart from the glazing element inner surface. The encapsulation material may be introduced between the stabilising member and the glazing element inner surface. 
     The stabilising member may be spaced apart from the glazing element. The encapsulation material may form an elongate section of the connector extending between the stabilising member and the glazing element. 
     The mould may form an outer surface of the connector. 
     The mould may be profiled such that the connector outer surface forms a continuation of at least one of the glazing element outer surface and the finisher component outer surface. 
     The glazing element and the finisher component abut against each other in the mould. 
     According to a further aspect of the present invention there is provided an encapsulated assembly for an exterior of a vehicle, the encapsulated assembly comprising:
         a first component having a first inner surface and a first outer surface, wherein a portion of the first inner surface forms a first encapsulation area; and   a second component having a second inner surface and a second outer surface, wherein a portion of the second inner surface forms a second encapsulation area;   the first component and the second component being connected to each other by a connector, the connector being composed of an encapsulation material which encapsulates the first encapsulation area and the second encapsulation area such that the encapsulated assembly comprises a substantially continuous outer surface;   wherein the second component comprises a stabilising member extending from the second inner surface and forming the second encapsulation area.       

     The first component and the second component may be formed from different materials. 
     According to a further aspect of the present invention there is provided a method of forming an encapsulated assembly for an exterior of a vehicle, the encapsulated assembly comprising a first component having a first inner surface and a first outer surface; and a second component having a second inner surface and a second outer surface; the method comprising:
         locating the first component and the second component in a mould;   introducing an encapsulation material into the mould to form a connector to connect the first component to the second component, the encapsulation material encapsulating a first encapsulation area formed on the first inner surface and a second encapsulation area formed on the second inner surface such that the encapsulated assembly comprises a substantially continuous outer surface. The mould may form an outer surface of the connector.       

     Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  shows a schematic representation of a vehicle incorporating a glazing assembly in accordance with an embodiment of the present invention; 
         FIG. 2  shows a perspective view of a vehicle incorporating the glazing assembly illustrated in  FIG. 1 ; 
         FIG. 3  shows a sectional view through the glazing assembly shown in  FIG. 2 ; 
         FIG. 4  shows a plan elevation of a mould for forming a connector to join the glazing element and the finisher component of the glazing assembly; 
         FIG. 5A  shows a sectional view of the mould shown in  FIG. 4  prior to introduction of an encapsulation material; 
         FIG. 5B  shows a sectional view of the mould shown in  FIG. 4  after introduction of the encapsulation material to form the connector; and 
         FIG. 6  shows a perspective view of a vehicle incorporating a known two-piece glazing assembly. 
     
    
    
     DETAILED DESCRIPTION 
     A glazing assembly  1  in accordance with an embodiment of the present invention is described herein with reference to the accompanying Figures. As shown in  FIGS. 1 and 2 , the glazing assembly  1  is installed on a vehicle  2 . In the present embodiment, the vehicle  2  is an automobile. In particular, the vehicle  2  is a sports utility vehicle (SUV). It will be understood that the glazing assembly  1  may be employed in a vehicle  2  having other body styles, for example a saloon, sports, coupe, station wagon, estate, shooting brake or utility. Furthermore, it will be understood that the glazing assembly  1  may be installed in other types of vehicle, such as a train. 
     As shown in  FIG. 1 , the vehicle  2  comprises a vehicle body (denoted generally by the reference numeral  3 ) comprising an A-pillar  4 , a B-pillar  5 , a C-pillar  6  and a D-pillar  7 . The glazing assembly  1  is a rear quarter glazing assembly and is installed in a rear quarter of the vehicle  2  so as to extend between the C-pillar  6  and the D-pillar  7 . The glazing assembly  1  comprises a glazing element  10  and a finisher component  11 . The finisher component  11  forms an exterior surface of the vehicle  2  (also known as an A-surface). 
     The glazing element  10  consists of a glass panel and forms a rear quarter window of the vehicle  2  when the glazing assembly  1  is installed. The rear quarter window in the present embodiment is a fixed window (i.e. a window which cannot be opened), but aspects of the present invention could be implemented in a window which can open. The glazing element  10  is fastened to the vehicle body  3  using conventional fastening means (not shown), such as an adhesive and/or one or more mechanical fastener(s). The glazing element  10  has an inner surface  10 A and an outer surface  10 B. The outer surface  10 B of the glazing element  10  forms part of the exterior surface of the vehicle  2  when the glazing assembly  1  is fitted. 
     The finisher component  11  comprises a D-pillar finisher which forms an exterior surface of the D-pillar  7  of the vehicle body  3 . The finisher component  11  is moulded from a plastics material, for example by an injection-moulding process. The D-pillar finisher is made of a thermoplastic Polymethyl methacrylate (P.M.M.A) in the present embodiment. As shown in  FIG. 3 , the finisher component  11  comprises a finisher panel  12 , a stabilising member  13  and a connector  14 . The finisher panel  12  comprises an inner surface  12 A and an outer surface  12 B. The outer surface  12 B of the finisher panel  12  forms a part of the exterior surface of the vehicle  2 . The outer surface  12 B of the finisher panel  12  may have a gloss or matt finish. The stabilising member  13  is provided to reinforce the connection between the glazing component  10  and the finisher component  11 . The stabilising member  13  projects from the inner surface  12 A of the finisher panel  12  and extends alongside the glazing component  10  to form an overlap. As shown in  FIG. 3 , the stabilising member  13  is spaced apart from the inner surface  10 A of the glazing element  10 . The finisher panel  12  and the stabilising member  13  are formed integrally such that the finisher component  11  has a one-piece composition. In a variant, the finisher panel  12  and the stabilising member  13  could be formed separately and then joined, for example by fastening or mounting the stabilising member  13  to the finisher panel  12 . 
     The connector  14  fixedly connects the glazing element  10  and the finisher component  11 . As described herein, the connector  14  is moulded around the stabilising member  13  and at least partially encapsulates the stabilising member  13 . The connector  14  retains the glazing element  10  and the finisher component  11  in a substantially fixed position and orientation relative to each other. The glazing assembly  1  may be fitted to the vehicle body  3  as a single, homogeneous component. The connector  14  may be at least substantially rigid or inflexible. In the present embodiment, the connector  14  enables limited relative movement of the glazing element  10  and the finisher component  11  to facilitate fitting of the glazing assembly  1 . The connector  14  could be formed from an elastomeric compound. 
     The connector  14  forms a joint J 1  (represented by a dashed line in  FIG. 2 ) between the glazing element  10  and the finisher component  11 . The joint J 1  is elongated along the length of the boundary between the glazing element  10  and the finisher component  11 . A sectional view of the joint J 1  is shown in  FIG. 3  and the joint J 1  extends out of the plane of the page. The joint J 1  comprises an outer surface  18  having a curved profile which forms a continuation of the outer surfaces  10 B,  12 B of the glazing element  10  and the finisher panel  12 . The outer surface  18  of the joint J 1  thereby forms a substantially continuous (i.e. substantially uninterrupted) exterior surface for the glazing assembly  1 . The continuous outer surface  18  forms a seamless joint J 1  which is less visible than prior art arrangements. The glazing element  10  has a first edge  15 ; and the finisher component  11  has a second edge  16 . The first and second edges  15 ,  16  each have a convex profile in transverse section. The joint J 1  is formed such that the first and second edges  15 ,  16  oppose each other in a spaced apart arrangement. In the present embodiment, a substantially uniform first gap G 1  is formed between the first and second edges  15 ,  16  along said joint J 1 . In a variant, the joint J 1  may be formed such that the first and second edges  15 ,  16  abut against each other. The first and second edges  15 ,  16  could have cooperating profiles to form the joint J 1 , for example cooperating convex and concave profiles. As shown in  FIG. 2 , in the present embodiment the joint J 1  comprises a linear section and a curved section in side elevation. It will be understood that the joint J 1  may have other profiles. 
     The stabilising member  13  extends continuously along the length of the joint J 1  and reinforces the connection between the glazing element  10  and the finisher component  11 . The stabilising member  13  extends across the joint J 1  to form an overlap with the glazing element  10 . As shown in  FIG. 3 , the stabilising member  13  is spaced apart from the inner surface  10 A of the glazing element  10 . In the present embodiment, the stabilising member  13  extends substantially parallel to the inner surface  10 A of the glazing element  10 . A second gap G 2  is formed between the stabilising member  13  and the inner surface  10 A of the glazing element  10 . As described herein, the connector  14  is formed in the second gap G 2 . One or more aperture may be formed in the stabilising member  13  to form a mechanical interlock between the stabilising member  13  and the connector  14 . As shown in  FIG. 3 , a channel  17  is formed at a base of the stabilising member  13  to form a keyed interlock with the connector  14 . 
     The connector  14  is moulded in situ such that it is formed around the glazing element  10  and the finisher component  11 . The glazing element  10  comprises a first encapsulation area A 1  formed on the inner surface  10 A. The stabilising member  13  comprises opposing surfaces which form respective second and third encapsulation areas A 2 , A 3 . The connector  14  is moulded onto the glazing element  10  and the finisher component  11  so as to form a bond directly with each of the first, second and third encapsulation areas A 1 -A 3 , thereby connecting the glazing element  10  and the finisher component  11 . A plan elevation of a mould  50  for forming the connector  14  is shown in  FIG. 4 . The mould  50  forms a mould cavity  51  in fluid communication with an injection port  52  through which an encapsulation material is injected to form the connector  14 . The mould  50  in the present embodiment comprises first and second mould members  53 ,  54  for forming the mould cavity  51 . At least one of the first and second mould members  53 ,  54  is movable to open and close the mould  50 . A sectional view of the mould  50  along the section line A-A of  FIG. 4  is shown in  FIGS. 5A and 5B . 
     The formation of the connector  14  will now be described with reference to  FIGS. 5A and 5B . The mould  50  is opened and the glazing element  10  and the finisher component  11  are located in the mould  50  in a desired position and orientation relative to each other. The first and second mould members  53 ,  54  are brought together to close the mould  50 . The first and second mould members  53 ,  54  clamp the glazing element  10  and the finisher component  11  in position. The glazing element  10  and the finisher component  11  are supported in the mould  50  spaced apart from each other. The first and second gaps G 1 , G 2  are thereby maintained between the glazing element  10  and the finisher component  11 . The glazing element  10  and the finisher component  11  are held in this position by the first and second mould members  53 ,  54 . The mould  50  forms the mould cavity  51  around the glazing element  10  and the finisher component  11  in the shape of the connector  14 . The first, second and third encapsulation areas A 1 -A 3  are open to an interior of the mould cavity  51 . 
     As illustrated in  FIG. 5B , the encapsulating material (or a tertiary material) is introduced into the mould cavity through the injection port  52 . The encapsulating material may, for example, comprise a thermoplastic elastomer (TPE), sometimes referred to as a thermoplastic rubber. The thermoplastic elastomer may provide both thermoplastic and elastomeric properties, for example enable moderate elongation. The thermoplastic elastomer typically has a low viscosity which enables injection at relatively low pressures. The encapsulation material fills the mould cavity  51  and at least substantially covers the first, second and third encapsulation areas A 1 -A 3 . The encapsulation material fills the first and second gaps G 1 , G 2  formed between the glazing element  10  and the finisher component  11 , thereby forming the joint J 1 . The mould cavity  51  is profiled to form the outer surface  18  of the joint J 1  as a continuation of the outer surface  10 B of the glazing element  10  and the outer surface  12 B of the finisher panel  12 . Thus, the outer surface of the glazing assembly  1  (as defined by the outer surfaces  10 B,  12 B and the outer surface  18 ) is at least substantially continuous and is at least substantially free from surface interruptions or discontinuities. The encapsulating material is cured to form the connector  14  which is bonded to each of the first, second and third encapsulation areas A 1 -A 3 . The mould is then opened and the glazing assembly  1  removed as a single component. 
     The glazing assembly  1  is pre-assembled for example to facilitate installation on the vehicle  2 . The glazing assembly  1  may be transported and manipulated as a single component, rather than a separate glazing element  10  and finisher component  11 . This facilitates fitting of the glazing assembly  1  to the vehicle body  3 , for example on the assembly line. The glazing assembly  1  may be removed from the vehicle body  3  as a single component, for example to replace a damaged unit. 
     It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application. 
     The surface of the glazing element  10  may optionally be etched, either mechanically or chemically, to provide a keyed surface finish in the first encapsulation area A 1 . Alternatively, or in addition, the finisher component  11  may be formed such that one or both of the second and third encapsulation areas A 2 , A 3  may have a textured or roughened surface finish for enhancing bonding. 
     The glazing assembly  1  has been described herein with particular reference to a D-pillar finisher assembly. It will be understood that the glazing assembly  1  could be used in other applications. The glazing assembly  1  could be used in conjunction with a front windshield, for example to form an A-pillar finisher assembly. Alternatively, the glazing assembly  1  could be used in conjunction with a rear windshield, for example to integrate a finisher component into a trunk door. 
     The method and apparatus described herein is not limited to glazing assemblies. For example, the glazing panel could be replaced with a plastic element, for example a transparent plastic element. The transparent plastic element may form a cover of a light on the vehicle, for example a front headlight, a tail light or a signalling light.