Method of mounting a seal on a substrate and assembly comprising a seal and a substrate

Abstract

The present disclosure relates to a method of mounting a preform seal on a substrate, comprising the steps of: providing a preform seal at a predetermined position relative to the substrate, at least a portion of the preform seal being spaced apart from the substrate by a distance; arranging a mold in contact with the substrate and the preform seal, wherein the mold holds the preform seal at the predetermined position, and wherein the mold, the substrate and the preform seal delimit a mold cavity. Further, the method comprises the steps of: at least partially filling the mold cavity with a settable composition, wherein the settable composition is in contact with the substrate and the preform seal to bridge said distance; setting the settable composition, whereby the settable composition forms a molded part attached to the preform seal and attached to the substrate. The preform seal and the settable composition are configured to be attached to each other. The present disclosure also relates to an assembly, an open roof assembly, a preform seal.

Description

Technical Field

[0001] This invention relates to providing a seal on a substrate (specifically a glass panel), and to an assembly including a seal and a substrate. Furthermore, this invention relates to an open-top vehicle assembly including such an assembly, and to the seal used in the method and the assembly. Background Technology

[0002] For the purpose of automobiles, and specifically for use in open roof assemblies such as sunroofs, it is known to provide a seal in the outer periphery or circumferential region of the panel (e.g., a movably arranged panel) of an open roof assembly, the seal being also referred to herein as a closing member.

[0003] In known components, the seal is formed by molding, which is performed simultaneously with encapsulating the edge region along the circumference of the panel with a solidifiable composition (e.g., a curable polyurethane). In this method, a mold is formed at the edge region, and a cavity within the mold is filled with the solidifiable composition. The mold cavity has a shape corresponding to the desired shape of the seal. After solidification (e.g., curing), the mold is removed, and the seal remains in the outer peripheral region. This method can be performed by pressure injection molding processes, such as RIM (Reactive Injection Molding), or by application under atmospheric pressure, such as WST (Window Spraying Technology).

[0004] A disadvantage of the above-described method of setting the seal is the limitation on the seal shape. Specifically, the seal shape is limited to an integral shape without any hollow cavity, whereas in some applications, a spherical seal, for example, with a hollow cavity to provide increased compressibility and adaptability, may be preferred. Such spherical seals are easily manufactured by extrusion and are typically provided with protrusions for mechanical connection to a support structure. This mechanically connected installation increases manufacturing steps and imposes additional requirements on the panel and the encapsulation provided on the panel. Summary of the Invention

[0005] The aim is to provide a cost-effective method for setting prefabricated seals for a substrate.

[0006] In a first aspect, a method for mounting a prefabricated seal onto a substrate is provided. The method includes the steps of: providing a substrate; positioning the prefabricated seal at a predetermined position relative to the substrate, at least a portion of the prefabricated seal being spaced apart from the substrate by a distance; arranging a mold, wherein the mold holds the prefabricated seal at the predetermined position, and wherein the mold, the substrate, and the prefabricated seal define a mold cavity; at least partially filling the mold cavity with a solidifiable composition, wherein the solidifiable composition contacts the substrate and the prefabricated seal to bridge the distance; and solidifying the solidifiable composition, whereby the solidifiable composition forms a molded component attached to the prefabricated seal and attached to the substrate. The prefabricated seal and the solidifiable composition are configured to be attached to each other. Therefore, in a single manufacturing step, the prefabricated seal and peripheral encapsulation or any other molded component can be positioned.

[0007] Well-known and commonly used solidifiable compositions include polyurethane compositions, which can be applied in a liquid state under pressure or atmospheric pressure and then cured to form a solid molded part. Nevertheless, polyurethane can have different compositions and corresponding properties.

[0008] Well-known and commonly used prefabricated seals include EPDM rubber, which is extruded. Like polyurethane, EPDM rubber comprises a range of different compositions and can have distinct properties. Furthermore, not every combination of a specific polyurethane and a specific EPDM will chemically adhere to each other, at least not with sufficient strength for automotive applications. Therefore, the curable composition and the prefabricated seal are configured to adhere to each other. This adhesion can be achieved through appropriate selection of the combination of the curable composition and the sealing composition, which can be treated as chemical adhesion. In other embodiments, chemical adhesion can be facilitated by using a base composition. Additionally, mechanical adhesion can be facilitated by providing coupling protrusions on the prefabricated seal, wherein the coupling protrusions are embedded in the molded part, as described in more detail below.

[0009] In embodiments of this method, the prefabricated seal is flexible. Therefore, for example, the prefabricated seal can be configured to correspond to the outer peripheral shape of the substrate, or it can be configured to provide sealing properties according to the specific application requirements of the seal. However, the flexibility is controllable. For example, a prefabricated seal comprising EPDM can have high flexibility, which can be reduced or at least controlled, for example, by embedding a more rigid and flexible element (e.g., a steel insert).

[0010] In embodiments of the method, the substrate includes a glass panel and the prefabricated seal includes a sealing portion configured to provide a sealing function for sealing the gap between the glass panel and a structure disposed thereon. Specifically, such a structure can be a vehicle body and the glass panel can be a window or a roof panel. Such a roof panel can be a fixed panel or a movable panel. The sealing portion can take any form, including any hollow structure, wherein the form is selected and manufactured according to the intended application. Furthermore, not only the form can be predetermined, but other characteristics can also be predetermined. For example, compressibility, abrasion resistance, resistance to external conditions such as rain and ultraviolet radiation, and other characteristics can be considered during the design and manufacture of the prefabricated seal. Because the seal is prefabricated, greater design freedom is achieved compared to seals formed through molding.

[0011] In an embodiment of the method, the prefabricated seal includes a first surface and a second surface, wherein the second surface is opposite to the first surface. Further, in the step of arranging the mold, the first surface is arranged facing the mold cavity; in the step of filling the mold cavity, a solidifiable composition is brought into contact with the first surface; and in the solidification step, the first surface is attached to the solidifiable composition. After solidification, the second surface does not contact the molded part. Therefore, the second surface of the prefabricated seal forms an outer surface covering the molded part. Specifically, the surface of the molded part may not be visually appealing. Using a prefabricated seal that covers the surface of the molded part reduces the requirements on the inner surface of the mold cavity because the surface of the molded part will be covered and invisible.

[0012] In an embodiment of the method, the prefabricated seal includes a cap portion. The cap portion is configured to at least partially cover the mold cavity. In this embodiment, the step of filling the mold cavity includes holding the cap portion in a first position to provide an opening to the mold cavity; providing a solidifiable composition through the opening; and positioning the cap portion in a second position, wherein the cap portion at least partially covers the mold cavity. This embodiment is particularly relevant to molding processes under atmospheric pressure, as the cap portion can be simply lifted partially or completely to provide an opening through which the solidifiable composition can be placed into the mold cavity. Of course, in certain embodiments, considering the requirement that such a cap portion can withstand the pressure generated within the mold cavity, a similar cap portion can be used in conjunction with a pressurized injection method.

[0013] In a particular embodiment of the method of setting a cap portion on a prefabricated seal, the cap portion is brought into contact with a solidifiable composition during the step of positioning the cap portion in a second position. In a more particular embodiment, the cap portion is brought into contact with the solidifiable composition at a time when chemical adhesion may occur between the solidifiable composition and the cap portion. Furthermore, it may be necessary, for example, that the solidifiable composition has not yet begun to solidify on its surface.

[0014] In embodiments of the method, the prefabricated seal includes an operating protrusion, wherein the mold placement step includes engaging the mold with the operating protrusion to hold the prefabricated seal in a predetermined position. The method also includes a step of disengaging the mold and the prefabricated seal. In a particular embodiment, disengagement is achieved by disconnecting the operating protrusion from the prefabricated seal. Therefore, the operating protrusion on the prefabricated seal can easily and accurately hold the prefabricated seal in its predetermined position during the molding process.

[0015] Further embodiments may be combined with aspects of the embodiments described above.

[0016] In one aspect, an assembly is provided comprising a substrate, a pre-formed seal, and a molded component. The molded component is attached to the substrate and to the pre-formed seal, thereby attaching the substrate and the pre-formed seal to each other.

[0017] In one embodiment of the component, the substrate includes a glass panel and a pre-fabricated seal includes a sealing portion. The sealing portion is configured to provide a sealing function for sealing the gap between the glass panel and the structure on which the glass panel is configured to be disposed.

[0018] In an embodiment of the component, the sealing element includes a cap portion that at least partially covers the molded part.

[0019] In embodiments of the component, the prefabricated seal includes a coupling protrusion that extends into the molded part and provides a mechanical connection between the prefabricated seal and the molded part. This mechanical connection can help increase adhesion strength.

[0020] In one aspect, a roof assembly is provided, wherein an open roof assembly includes embodiments of the aforementioned assembly. This roof assembly can be configured, for example, to be mounted as part of the roof of a vehicle.

[0021] In another aspect, a prefabricated seal is provided, wherein the prefabricated seal is configured for use in embodiments of the above-described method or configured to be included in embodiments of the above-described components. Furthermore, the prefabricated seal is configured to adhere to a predetermined solidifiable composition, preferably a predetermined solidifiable polyurethane composition. Attached Figure Description

[0022] The further scope of the invention will become apparent from the detailed description given below. However, it should be understood that the detailed description and specific examples, while illustrating embodiments of the invention, are given by way of illustration only, as various changes and modifications within the scope of the invention will become apparent to those skilled in the art from the detailed description with reference to the accompanying schematic diagrams, wherein:

[0023] Figure 1A A perspective view of the roof with an open roof assembly is shown;

[0024] Figure 1B It shows Figure 1A Exploded view of the open roof assembly;

[0025] Figure 2A A cross-sectional view of a prior art embodiment of a substrate with a seal is shown;

[0026] Figure 2B Explained manufacturing Figure 2A The method of the embodiment;

[0027] Figure 3 A cross-sectional view of a first embodiment of a substrate with pre-fabricated seals is shown;

[0028] Figure 4A -4D illustrates manufacturing Figure 3 The method of the first embodiment.

[0029] Figures 5A-5D illustrate a method for manufacturing a substrate with a pre-fabricated seal, according to a second embodiment.

[0030] Figures 6A-6D illustrate a method for manufacturing a substrate with a pre-fabricated seal according to a third embodiment;

[0031] Figure 7A A cross-sectional view of a fourth embodiment of a substrate with pre-fabricated seals is shown;

[0032] Figure 7B A cross-sectional view of a fifth embodiment of a substrate with pre-fabricated seals is shown;

[0033] Figure 7C A cross-sectional view of a sixth embodiment of a substrate with pre-fabricated seals is shown;

[0034] Figure 8A A method for manufacturing a substrate with pre-fabricated seals according to a seventh embodiment is described;

[0035] Figure 8B shows Figure 8A A cross-sectional view of the seventh embodiment;

[0036] Figure 8C shows a cross-sectional view of an eighth embodiment of a substrate with pre-fabricated seals;

[0037] Figure 8D shows a cross-sectional view of a ninth embodiment of a substrate with pre-fabricated seals.

[0038] Specific embodiments

[0039] The invention will now be described with reference to the accompanying drawings, wherein the same reference numerals are used in various views to identify the same or similar elements.

[0040] Figure 1A The diagram illustrates the roof 1 in which an open roof assembly is arranged. The open roof assembly includes a movable panel 2a and a fixed panel 2b. The movable panel 2a is also referred to as a closing member because it is movable above a first roof opening 3a, thereby enabling the first roof opening 3a to be opened and closed. A vent 4 is arranged at the front side of the first roof opening 3a.

[0041] In the illustrated embodiment, the movable panel 2a can be in a closed position, which is the position in which the movable panel 2a is arranged above and closes the first roof opening 3a, and is therefore generally arranged in the plane of the roof 1. Furthermore, the movable panel 2a can be in an inclined position, which is the position in which the rear end RE of the movable panel 2a is raised compared to the closed position, while the front end FE of the movable panel 2a remains in the closed position. Additionally, the movable panel 2a can be in an open position, which is the position in which the movable panel 2a slides open and the first roof opening 3a is partially or completely exposed.

[0042] It should be noted that the roof 1 shown corresponds to a passenger vehicle. However, the invention is not limited to passenger vehicles. It is also conceivable that any other type of vehicle may be equipped with a movable panel.

[0043] Figure 1B Explained with Figure 1A The roof shown has the same panels 2a and 2b. Specifically, although Figure 1A The open roof assembly in the open position is shown, but Figure 1B This is an exploded view of the open roof assembly in the closed position. Furthermore, in Figure 1B The exploded view shows the presence of a second roof opening 3b. The first roof opening 3a and the second roof opening 3b are disposed within the frame 5 of the open roof assembly, with a central beam 12 of the frame 5 between the openings 3a and 3b. The edge 5a of the frame 5 defines the first roof opening 3a.

[0044] The second roof opening 3b is arranged below the fixed panel 2b, allowing light to enter the vehicle's interior passenger compartment through the fixed panel 2b, assuming the fixed panel 2b is a glass panel or a similar transparent panel, for example, made of plastic or any other suitable material. The second roof opening 3b with a transparent or translucent fixed panel 2b is optional and can be omitted in another embodiment of the open roof assembly.

[0045] The air guide plate 4 is typically made of a flexible material, such as a woven or nonwoven fabric, a web, or a mesh with through-holes arranged therein. The flexible material is supported by a support structure 4a (e.g., a rod-like or tubular structure), which is directly or indirectly hinged to the frame 5 at a hinge joint 4b.

[0046] The air deflector 4 is positioned in front of the first roof opening 3a and adjusts airflow when the movable panel 2a is in the open position. In the raised position, the air deflector 4 reduces inconvenient noise caused by airflow during driving. When the movable panel 2a is in the closed or tilted position, the air deflector 4 is pressed downwards below the front end FE of the movable panel 2a.

[0047] Normally, when the movable panel 2a slides to the open position, the air guide plate 4 rises due to elasticity, and when the movable panel 2a slides back to its closed position, the air guide plate 4 is pushed downward by the movable panel 2a. Figure 1A In the image, the movable panel 2a is shown in the open position, and the air guide plate 4 is shown in the raised position. Figure 1B In the diagram, the movable panel 2a is shown in the closed position, and the air guide plate 4 is correspondingly shown in the position where it is pressed downwards.

[0048] Figure 1B A drive assembly with a first guide component 6a, a second guide component 6b, a first drive cable 7, and a second drive cable 8 is further shown. The first guide component 6a and the second guide component 6b are arranged on corresponding side ends SE of the movable panel 2a, and each may include a guide and a mechanism. The guide is coupled to the frame 5, and the mechanism includes a movable portion and is slidably movable within the guide. The first drive cable 7 and the second drive cable 8 are disposed between the mechanism of the respective guide components 6a, 6b and the electric motor 9.

[0049] Drive cables 7 and 8 connect electric motors 9 to the mechanisms of the corresponding guide components 6a and 6b, such that the mechanisms begin to move when the electric motor 9 is operated. Specifically, the cores of drive cables 7 and 8 move via the electric motor 9, thereby pushing or pulling the mechanisms of the corresponding guides 6a and 6b. Such drive components are well known in the art and therefore will not be further described herein. Furthermore, any other suitable drive components can be used without departing from the scope of the invention. Moreover, in certain embodiments, the electric motors can be operably arranged between the corresponding guides and mechanisms of the guide components 6a and 6b, and in such embodiments, the drive components can be completely omitted.

[0050] In the illustrated embodiment, guide components 6a, 6b can begin to move as the rear end RE of the movable panel 2a is raised, thereby bringing the movable panel 2a to an inclined position. Then, guide components 6a, 6b can slide from the inclined position to bring the movable panel 2a to an open position. However, the invention is not limited to this embodiment. For example, in another embodiment, the movable panel 2a can be moved to the inclined position by raising the rear end RE, while the open position is reached by first lowering the rear end RE and then sliding the movable panel 2a under the fixed panel 2b or any other structure or element disposed behind the rear end RE of the movable panel 2a. In another exemplary embodiment, the movable panel 2a may be movable only between a closed position and an inclined position, or only between a closed position and an open position.

[0051] In the illustrated embodiment, the electric motor 9 is mounted near or below the front end FE of the movable panel 2a at the recess 10. In another embodiment, the electric motor 9 can be positioned at any other suitable location. For example, the electric motor 9 can be arranged near or below the rear end RE of the movable panel 2a or below the fixed panel 2b.

[0052] Control module 11 is schematically shown and operatively coupled to electric motor 9. Control module 11 can be any type of processing module, a software-controlled processing module, or a dedicated processing module (e.g., an ASIC), all of which are well known to those skilled in the art. Control module 11 can be a standalone control module, or it can be operatively connected to another control module, such as a multipurpose, universal vehicle control module. In yet another embodiment, control module 11 can be embedded in or as part of such a universal vehicle control module. Essentially, control module 11 can be embodied by any control module suitable for, capable of, and configured to perform operations on electric motor 9 and thus on the movable roof assembly.

[0053] Figure 2AA prior art component 2 is shown, comprising a substrate (specifically, a glass panel 20) and a molded component 30. Component 2 can be used as a panel for a vehicle roof, for example... Figure 1A and 1B Examples of movable closure members 2a or fixed panels 2b are described. For use in vehicle roofs, the assembly is not required to include a glass panel 20, but may also include any other suitable and desired substrate. For example, a transparent plastic substrate may be used alternatively. In another embodiment, the substrate may be opaque or translucent and may be formed, for example, from glass, plastic, or metal.

[0054] The molded component 30 includes a main body portion 31 and a sealing portion 32. The main body portion 31 is attached to the outer peripheral portion 23 of the glass panel 20. The outer peripheral portion 23 is adjacent to the edge of the glass panel 20. In this embodiment, the main body portion 31 covers a portion of the outer peripheral portion 23, for example, to cover a portion of the roof disposed below the outer peripheral portion 23. However, it is not necessary for the outer peripheral portion 23 to be completely covered. It is necessary for the molded component 30 to be sufficiently attached to the substrate (e.g., the glass panel 20).

[0055] The sealing portion 32 is a flexible portion of the molded part 30 that extends outward from the outer peripheral portion 23. When the glass panel 20 is installed in the roof, the flexible sealing portion 32 can contact a portion of the roof and thus close or cover that portion, preventing airflow, water ingress, noise, or any other similar adverse phenomena as known in the art.

[0056] Figure 2B Explanation of settings Figure 2A This relates to existing methods for creating seals. In this method, a liquid, solidifiable composition is supplied into a mold cavity under atmospheric pressure, thus allowing the mold cavity to be open to reduce the requirements on the mold. One embodiment of this method is known as window spraying (WST). It should also be noted that similar seals can be created using a molding process in which the liquid composition is placed into the mold cavity under increased pressure, such as reaction injection molding (RIM).

[0057] In the illustrated embodiment of the method, a first mold component 41, a second mold component 42, and a third mold component 43 are arranged to form a mold cavity. The first mold component 41 includes a first support element 411, a second support element 412, and a mold forming element 413. The mold forming element 413 is formed into a shape opposite to the desired shape of the molded component 30. Furthermore, the material and surface finish of the mold forming element 413 can be selected according to the desired surface finish of the molded component 30. For example, it is known that the mold forming element 413 comprises silicone rubber, providing a high-quality surface finish for the molded component 30.

[0058] The second mold component 42 is illustrated as a single unit. However, in practice, the second mold component 42 may include multiple elements. For example, additional mold forming elements similar to mold forming element 413 may be arranged to form the molded part 30 and / or provide the desired surface finish.

[0059] The third mold component 43 includes a third support element 431 and a fourth support element 432. The four support elements 411, 412, 431, and 432 are supported on the glass panel 20 to arrange the first and third mold components 41 and 43 relative to the glass panel 20. For example, the second mold component 42 may be arranged on and positioned relative to the first mold component 41. Thus, a mold cavity is formed, defined by the glass panel 20, the mold forming element 413, the second mold component 42, the third mold component 43, and the fourth support element 432. An opening leading to the mold cavity is provided between the second and third mold components 42 and 43. Through the opening, a liquid, solidifiable composition can be added to the mold cavity. In the mold cavity, the solidifiable composition solidifies to form the molded component 30.

[0060] The molded part 30 can be formed from any suitable solidifiable composition, wherein the molded part 30 is attached to the glass panel 20 during molding. Solidification can include solidification by cooling, thermal curing or radiation curing, hardening, vulcanization or any other suitable and known method. In one embodiment, the composition may consist of two or more components aggregated together in the mold cavity for a chemical hardening reaction. Many methods and compositions for solidifying liquid compositions are known to those skilled in the art, and suitable compositions can be selected for the application illustrated and described. After solidification, the first, second, and third molded parts 41, 42, and 43 are removed.

[0061] Figure 3 A first embodiment of component 2 is described, which includes a glass panel 20, a molded component 30, and a pre-fabricated seal 50. (See also: Regarding...) Figure 2A As described, the glass panel 20 can be any other suitable and desired type of substrate.

[0062] In this embodiment, the prefabricated seal 50 includes a central portion 51 and a sealing portion 52, wherein a hollow cavity 52a is provided, for example, to control the flexibility of the sealing portion 52. This shape of the sealing portion 52 with the hollow cavity 52a cannot be obtained by the aforementioned prior art methods. However, the present invention is not limited to any particular shape or function of the sealing portion 52.

[0063] The central portion 51 is attached to the glass panel 20 via a molded component 30 comprising the body portion 31. Thus, in this embodiment, the molded component 30 is attached to both the glass panel 20 and the pre-formed seal 50. Therefore, suitable solidifiable compositions can be selected, suitable compositions for the pre-formed seal can be selected, and / or a primer composition can be provided between the molded component 30 and the pre-formed seal 50 and / or between the molded component 30 and the glass panel 20. Typically, the molded component 30 may comprise a polyurethane (PU) composition and the pre-formed seal 50 may comprise an ethylene propylene diene monomer (EPDM) rubber composition. Both PU and EPDM compositions comprise a variety of compositions; some combinations of PU and EPDM may have weaker adhesion, while others may exhibit strong adhesion. Those skilled in the art are capable of determining suitable combinations of such PU and EPDM or any other suitable composition exhibiting sufficient adhesion strength for use in component 2 (e.g., for use in a vehicle roof), optionally supported by the primer composition.

[0064] The prefabricated seal 50 can be formed, for example, by extrusion. Extrusion allows elongated plastic-rubber sealing elements to be formed into a wide variety of cross-sectional shapes at low cost. Forming the sealing portion 52 by extrusion rather than molding reduces costs while increasing design freedom. Furthermore, the prefabricated seal 50 can be manufactured by any other suitable method. The invention is not limited to any particular method of manufacturing the prefabricated seal 50.

[0065] Figure 4A -4D describes the method used to obtain Figure 3 The method of the first embodiment. In this method, first, second, and third mold components 41, 42, and 43 are provided to form a mold cavity. (Regarding...) Figure 2B Compared to the prior art methods illustrated and described, the first mold component 41 does not include a mold forming element 413. Instead, a fifth support element 414 is provided. The requirements for the fifth support element 414 can be reduced compared to the requirements for the mold forming element 413.

[0066] In this particular embodiment, the second mold component 42 is provided only to support the central portion 51 of the prefabricated seal 50. Therefore, the requirements for the second mold component 42 can be reduced.

[0067] As shown in Figure 4B, the first, second, and third mold components 41, 42, and 43, as well as the glass panel 20 and the prefabricated seal 50, are positioned relative to each other to form a mold cavity 44 with a filling opening 45, wherein the mold cavity 44 is defined by the glass panel 20, the fifth support element 414 of the first mold component 41, the prefabricated seal 50, the third mold component 43, and the fourth support element 432.

[0068] A pre-formed seal 50 is disposed between the first mold component 41 (specifically the fifth support element 414) and the second mold component 42. The pre-formed seal 50 can be slightly compressed to ensure an impermeable transition between the pre-formed seal 50 and the fifth mold support element 414, preventing leakage of the solidifiable composition when it is introduced into the mold cavity 44.

[0069] In the next step, and as shown in Figure 4C, the solidifiable composition is disposed in the mold cavity 44 through the nozzle 60. In this particular embodiment, the mold cavity 44 and the solidifiable composition are under atmospheric pressure. If a pressurized method is used, the requirements for the mold components will be different. Those skilled in the art are capable of providing suitable molds for this method, where special care may be needed to prevent the preformed seal 50 from being compressed during molding to the extent that the preformed seal 50 loses its desired shape, flexibility, and / or compressibility.

[0070] Once placed in the mold cavity 44, the solidifiable composition can solidify to form the molded part 30. In the illustrated embodiment, the molded part 30 includes a central portion 31 and a sealing support portion 33.

[0071] Figure 4D illustrates the removal of mold components 41, 42, and 43, leaving... Figure 3 The first embodiment.

[0072] Figures 5A-5D illustrate a method, which, in terms of the processing steps involved, is essentially similar to... Figure 4A -4D Method. In the illustrated method, a second embodiment of component 2 is provided. In this second embodiment, the prefabricated seal 50 is provided with a central portion 51, a sealing portion 52, and a cover portion 53. The cover portion 53 is arranged at the filling opening 45 shown in FIG. 4B, through which the liquid solidifiable composition is supplied to the mold cavity 44. In the embodiments shown in FIG. 5A-5D, three mold components 41, 42, 43 are provided and arranged (FIG. 5A and 5B), wherein the cover portion 53 closes the gap between the second and third mold components 42, 43. In another embodiment, the cover portion 53 may only partially cover the gap, as will be apparent to those skilled in the art.

[0073] In the next processing step shown in Figure 5C, the injection nozzle 60 is positioned between the third mold component 43 and the cap portion 53 by lifting the cap portion 53. Therefore, the cap portion 53 can be flexible, or a hinged portion can be provided in the pre-formed seal 50 to allow the cap portion 53 to be lifted. The injection nozzle 60 injects a solidifiable composition into the mold cavity 44 to form the molded component 30. As shown in Figure 5D, the three mold components 41, 42, and 43 can then be removed.

[0074] In the second embodiment, after the solidifiable composition is injected, the cap portion 53 is released to cover the solidifiable composition. Depending on the characteristics of the cap portion 53, the characteristics of the solidifiable composition—specifically, its characteristics related to solidification, the filling level of the mold cavity, and processing characteristics—the cap portion 53 may be disposed on the surface of the molded part 30. The cap portion 53 may or may not be attached to the molded part 30. Those skilled in the art are capable of selecting appropriate characteristics to achieve attachment or non-attachment for the different elements and processing steps involved, based on the desired adhesion results.

[0075] A cap portion 53 can be provided to cover the surface of the molded part 30 at the filling opening 45 because this surface may have a less aesthetically pleasing and unattractive surface finish compared to other visible portions of the surface of the molded part 30. For example, the surface portion 33a of the sealing support portion 33 of the molded part 30 is visible. The finish of the surface portion 33a is defined and controlled by the fifth support element 414. As described above, the surface finish can be appropriately defined and controlled by such a mold cavity surface. During injection at the location of the injection nozzle 60, the surface finish cannot be controlled and may result in a less attractive surface finish. In this embodiment, a clear and controlled visible surface finish is achieved by covering the surface of the molded part 30 with a cap portion 53 having a pre-formed and aesthetically pleasing surface finish.

[0076] Figures 6A-6D illustrate a method that is substantially similar to the method in Figures 5A-5D in terms of the processing steps involved. In the embodiments shown in Figures 6A-6D, the processing of the prefabricated seal 50 becomes easier.

[0077] As shown in Figure 6A, the prefabricated seal 50 is provided with an operating protrusion 54, which in this embodiment extends from the central portion 51. Of course, depending on, for example, processing requirements, mold design, or the visual appearance after processing, the prefabricated seal 50 may have more than one operating protrusion, or the operating protrusion 54 may be positioned at another portion of the prefabricated seal 50.

[0078] In addition, the second mold component 42 includes a first sub-component 42a and a second sub-component 42b.

[0079] Figure 6B illustrates the arrangement of mold components 41, 42, 43, glass panel 20, and prefabricated seal 50, wherein the operating protrusion 54 is sandwiched between the first sub-component 42a and the second sub-component 42b of the second mold component 42. Therefore, the second mold component 42 is configured to hold the prefabricated seal 50 in place.

[0080] After forming the molded part 30 as shown in FIG. 6C, the three molded parts 41, 42, and 43 are removed as shown in FIG. 6D. When the second molded part 42 is removed, the operating protrusion 54 can be retained and the operating protrusion 54 can be disconnected from the pre-formed seal 50. Therefore, the second molded part 42 can be disengaged in a predetermined manner. For example, a predetermined sliding movement can be employed. Alternatively, a cutting device can be employed. In another embodiment, the operating protrusion 54 can be disengaged through the second molded part 42, and thereafter, the operating protrusion 54 is separated by a separate tool such as a cutting device. In yet another embodiment, the operating protrusion 54 can be retained on the pre-formed seal 50, for example, if the operating protrusion is not visible after further assembly of the final product or if the operating protrusion is used for another function, etc.

[0081] Those skilled in the art can freely choose a suitable shape and position for the operating protrusion 54. For example, as shown, the operating protrusion 54 may have a narrow connecting portion (in the illustrated cross-sectional view) at the transition to the central portion 51, such that only a few marks or no marks are left on the outer surface of the central portion 51 when the connection is broken. On the other hand, if a greater holding force is required during processing, a wide connecting portion (in the illustrated cross-sectional view) is appropriate, as will be apparent to those skilled in the art.

[0082] Figure 7A A fourth embodiment of component 2 is shown. In this fourth embodiment, the prefabricated seal 50 includes connecting protrusions. Specifically, a first connecting protrusion 56a and a second connecting protrusion 56b. The connecting protrusions 56a and 56b are embedded in the molding member 30 during molding and are shaped to be anchored in the molding member 30. Therefore, the connecting protrusions 56a and 56b increase the mechanical connection strength between the prefabricated seal 50 and the molding member 30. Obviously, any suitable number of connecting protrusions and any suitable location and position of such connecting protrusions can be selected according to technical requirements.

[0083] Furthermore, in the fourth embodiment, the prefabricated seal 50 includes first and second reinforcing elements 55a and 55b, respectively. For example, the reinforcing elements may include steel or another metal. In another embodiment, the reinforcing elements may include a plastic material. The reinforcing elements 55a and 55b may improve the final shape and corresponding visual appearance, or may be provided for technical considerations (e.g., strength) for manufacturing reasons or for the technical characteristics of the final component 2. In one embodiment, the reinforcing elements may extend to the connecting protrusions 56a and 56b or extend into the sealing portion 52.

[0084] As will be apparent to those skilled in the art, the connecting protrusions 55a, 55b and the reinforcing elements 56a, 56b can be as follows: Figure 7A The examples show combinations, but they can also be used individually, meaning one can be present while the other is absent.

[0085] Figure 7B The fifth embodiment is described, wherein the molded component 30 includes a surface extension 34 that extends from the visible surface portion 33a and covers the prefabricated seal 50. Therefore, the transition seam between the molded component 30 and the prefabricated seal 50 is removed from visibility.

[0086] For the same reason, such as Figure 7C As shown in the sixth embodiment, the pre-fabricated seal 50 may be provided with an extension 57 extending from the sealing portion 52 to the glass panel 20, thereby removing the molded component 30 from visibility. To ensure a strong and durable connection between the extension 57 and the molded component 30, a connecting protrusion 56c may be provided at the extension 57. Additionally or alternatively, a reinforcing element may be arranged in the extension 57.

[0087] Instead of installing prefabricated seals as described above, other types of components can also be installed on the outer periphery of the molded part 30. For example, in... Figure 8A In the embodiment shown in -8D, electronic components 80 may be installed.

[0088] refer to Figure 8A The third mold component 43 can be configured to hold one or more elements to be installed during molding. The frame element 71 can be held and installed, as is known in the art, by over-molding a portion of the frame element 71. This frame element 71 is typically made of steel and preferably does not directly contact the glass panel 20. Therefore, embedding it into the molding component 30 is a suitable method of joining the glass panel 20 and the frame element 71. The frame element 71 can then be used, for example, to mount the glass panel 20 onto a vehicle roof.

[0089] The electronic component 80 shown in the figure includes a printed circuit board (PCB) 81, an LED unit 82, additional electronic circuitry 83, and first and second PCB supports 84a and 84b. In the central region (i.e., outside the peripheral region), as is known in the art, another glass sheet 21 is attached to the glass panel 20 via a sandwich 22. The LED unit 82 is arranged and mounted such that light emitted by the LED unit 82 enters the other glass sheet 21, where it is conducted. This light can be coupled out from the other glass sheet 21 to enter the vehicle compartment for ambient lighting, as is known in the art and will not be further described here.

[0090] The third and fourth support elements 431 and 432 are positioned on the third mold component 43 such that they can engage the PCB 81 and apply pressure to the PCB 81 toward the glass panel 20. Thus, on the one hand, the electronic component 80 is held in place during molding, and on the other hand, a liquid-impermeable connection is formed between the fourth support element 432 and the PCB 81, and a liquid-impermeable connection is formed between the second PCB support 84b and the glass panel 20. Of course, other well-known measures for obtaining liquid-impermeable connections can also be applied.

[0091] After molding, the end portion of PCB81 is embedded in the component holding portion 35 of the molding component 30. After the mold components 41, 42, and 43 disengage, the seventh embodiment of component 2 is held as shown in FIG8B.

[0092] As described above regarding the adhesion between the preformed seal 50 and the solidifiable composition of the molded component 30, the adhesion strength between the electronic component 80 and the solidifiable composition can be designed by selecting suitable materials, including the application of, for example, a base composition or other support composition. Specifically, when bonding with electronic components, electrical properties may also need to be considered.

[0093] Additionally or alternatively, mechanical properties can be configured to increase adhesion strength. For example, as used in the eighth embodiment shown in FIG. 8C, a component connection protrusion 85 can be used. This component connection protrusion 85 can be a metal element that is connected to the PCB 81 and embedded in the component holding portion 35 of the molded component 30. In another example, as used in the ninth embodiment shown in FIG. 8D, a component connection through-hole 86 disposed in the PCB 81 can be used.

[0094] This component connection through-hole 86 can be embedded in the component retaining portion 35 of the molded component 30. It will be apparent to those skilled in the art that the through-hole 86 can be replaced by one or more recesses that provide the same connection function.

[0095] It should be noted that in the seventh, eighth, and ninth embodiments, the mounting of the electronic component 80 is shown in conjunction with the mounting of a prefabricated seal 50 to which the same molded component 30 is mounted. It is conceivable that the mounting of the prefabricated seal 50 and the mounting of the electronic component can be independent of each other. Therefore, the electronic component 80 can be mounted without the prefabricated seal 50 or with a separate molded component 30. Furthermore, it can be combined with, for example... Figure 2A and Figure 2B The prior art molded sealing portion 32 shown is combined with the mounting electronic component 80.

[0096] Furthermore, in the seventh, eighth, and ninth embodiments, the PCB 81 of the electronic component 80 is embedded in the molding member 30 only at a relatively small end portion. In another embodiment, a larger portion of the electronic component 80 may be embedded. Specifically, if the composition of the molding member 30 is non-conductive, the electronic component 80 may be largely covered or embedded, for example, to protect the electronic component 80 from moisture, mechanical shock, etc.

[0097] Detailed embodiments of the invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the invention, which may be embodied in various forms. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as the basis of the claims and as a representative basis for teaching those skilled in the art to apply the invention in various ways with any suitable detailed structure contemplated. Specifically, features presented and described in the individual dependent claims may be applied in combination, and any advantageous combination of such claims is disclosed herein.

[0098] Furthermore, it is anticipated that structural elements can be fabricated using three-dimensional (3D) printing technology. Therefore, any reference to a structural element is intended to include any computer-executable instructions instructing a computer to generate such a structural element using 3D printing technology or a similar computer-controlled manufacturing technique. Additionally, any such reference to a structural element is also intended to include a computer-readable medium carrying such computer-executable instructions.

[0099] Furthermore, the terminology and phrases used herein are not intended to be restrictive, but rather to provide an understandable description of the invention. As used herein, the term "a" or "an" is defined as one or more. As used herein, the term "a plurality" is defined as two or more. As used herein, the term "another" is defined as at least a second or more. As used herein, the terms "including" and / or "having" are defined as including (i.e., open-ended language). The term "connection" as used herein is defined as a link, but not necessarily a direct link.

[0100] The invention described herein can obviously be modified in many ways. Such modifications should not be considered as departing from the spirit and scope of the invention, and all such modifications that will be obvious to those skilled in the art are intended to be included within the scope of the appended claims.

Claims

1. A method for mounting a prefabricated seal on a substrate, the method comprising the following steps: a. Provide substrate; b. A prefabricated seal is provided at a predetermined position relative to the substrate, at least a portion of the prefabricated seal being spaced apart from the substrate by a certain distance; c. Arranging a mold, wherein the mold holds the prefabricated seal at the predetermined position, and wherein the mold, the substrate, and the prefabricated seal define a mold cavity; d. The mold cavity is at least partially filled with a solidifiable composition, wherein the solidifiable composition contacts the substrate and the pre-formed seal to bridge the distance; and e. Solidify the solidifiable composition so that the solidifiable composition forms molded parts attached to a pre-made seal and attached to a substrate; The prefabricated seal and the solidifiable composition are configured to adhere to each other. The prefabricated seal includes a cover portion configured to at least partially cover the mold cavity, and step d includes: d1. The cover portion is held in the first position, thereby providing an opening to the mold cavity; d2. Providing a solidifiable composition through an opening; and d3. Position the cover portion in the second position, wherein the cover portion at least partially covers the mold cavity.

2. The method according to claim 1, wherein, The prefabricated seal is flexible.

3. The method according to claim 1, wherein, The substrate includes a glass panel, and the prefabricated seal includes a sealing portion configured to provide a sealing function for sealing the gap between the glass panel and a structure on which the glass panel is configured to be disposed.

4. The method according to claim 1, wherein: • The prefabricated seal includes a first surface and a second surface, the second surface being opposite to the first surface, and in step c, the first surface is oriented toward the mold cavity; • In step d, the solidifiable composition is brought into contact with the first surface; • In step e, the first surface is attached to the solidifiable composition; • After step e, ensure that the second surface does not contact the molded part.

5. The method according to claim 1, wherein, In step d3, the cap portion is brought into contact with the solidifiable composition.

6. The method according to claim 1, wherein, The prefabricated seal includes an operating protrusion, and step c includes engaging the mold with the operating protrusion to hold the prefabricated seal in the predetermined position; and the method further includes step f, which includes disengaging the mold and the prefabricated seal.

7. The method according to claim 6, wherein, Step f includes disconnecting the operating protrusion from the prefabricated seal.

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