Low profile outer belt seal with improved retention

Abstract

This document presents a system and method for installing a thin outer strap seal having features capable of providing high-level retention of a door assembly. The outer strap seal includes a linear insert having two opposing outer sides. On at least one of the opposing outer sides, a clamping structure protrudes to achieve a friction-based connection between the outer strap seal and the wall of an opening into which a lower extension is inserted. A sealing lip extends from the linear insert and is arranged to contact a movable window capable of vertical translation near the strap seal. The sealing lip forms a sealing surface that prevents water from translating downwards from the movable window into the door assembly.

Description

[0001] Cross-references to related applications

[0002] This disclosure claims the benefit of U.S. Provisional Application No. 63 / 226,488, filed July 28, 2021, which is incorporated herein by reference in its entirety.

[0003] introduction

[0004] This disclosure relates to systems and methods for reducing the amount of visible outer strap seals in a door assembly, and more specifically, to systems and methods incorporating outer strap seals having features capable of providing a high level of retention for the door assembly. Summary of the Invention

[0005] A strap-on seal is used to form a seal against an actuating window within a door assembly to restrict or prevent fluid intrusion into the body of the door assembly. The strap-on seal is positioned between the door panel and the surface of the actuating window. The top of the door assembly typically utilizes an upward-pointing flange or lip as the connection point for the strap-on seal, resulting in a large, visible protruding surface formed by the strap-on seal when attached to the flange or lip of the door assembly. Current methods expose at least a portion of the strap-on sealing material and may or may not incorporate one or more covering elements to conceal or cover the exposed portion of the strap-on seal. However, the covering elements and / or the strap-on sealing material remain visible and protruding relative to the external door panel.

[0006] These and other drawbacks are addressed by the exemplary strap sealing structures and door assemblies described herein, wherein, for example, a portion of the strap sealing structure is recessed into the opening. In some embodiments, the strap sealing structure includes a linear insert having two opposing outer sides. The linear insert mates with an opening having two opposing inner surfaces. The linear insert has a first outer side, which is structured as a clamping surface based on the geometry of that side. When the linear insert is positioned in its mating opening, the clamping structure engages with the first inner surface in the inner surface to retain the linear insert in the opening. For example, the clamping structure may deform such that friction between the clamping structure and the inner surface increases. Additionally, a sealing lip is coupled to the linear insert and structured such that when the linear insert is positioned in the opening, the sealing lip contacts a movable window to form a watertight seal against the window, thereby preventing water from entering the door in which the window moves. As used in this disclosure, the term coupling may include connecting two separate pieces or more than one structure as a separate piece, but rather a continuously integrated structure.

[0007] These technologies address the problems of the other methods mentioned above. In particular, this method does not rely on a covering layer as a primary or sole mode for reducing the protrusion of the cable tie seal or decreasing its visibility. Instead, the insert is structured to be positioned within a U-shaped channel that forms a recess facing the top of the exterior door panel, such that the body of the insert is recessed from the view when the insert is in the installation position. Additionally, a clamping structure increases friction between the insert and the walls of the opening into which it is positioned. Therefore, due to this structure, the insert remains fixed and is not easily displaced once positioned. Furthermore, this method reduces the complexity of the door assembly by incorporating the opening for the insert into the existing panel in which the insert is positioned, the existing panel having a recessed U-shaped channel formed by the topmost portion of the panel. By incorporating this continuous feature, instead of reducing the visibility of the cable tie seal material by adding a structure to the panel to form an opening for the insert or by adding a covering layer, the U-shaped channel reduces component count and assembly complexity by reducing the visibility of the cable tie seal material or covering assembly.

[0008] In some embodiments, the strap seal includes a strap sealing structure having a body. The body has an upper portion and a lower portion that inserts into an opening in a U-shaped channel. In some embodiments, the upper portion is structured to secure a cap. When the linear insert is positioned in the opening of the U-shaped channel, the upper portion of the body extends above the opening. A first contact surface is formed between the sealing lip and a window that moves within the door assembly. A first arm includes an extension from the body and allows the sealing lip to form the first contact surface.

[0009] In some embodiments, the second contact surface is formed by a second arm extending from the body or the first arm to the movable window. For example, the second arm may attach the second contact surface to an upper portion of the body, or it may attach the second contact surface to the first arm extending from the body. Additionally, the first and second contact surfaces may be combined with a mechanically fixed abrasion-resistant material layer that reduces drag and friction between the surfaces in contact with the movable glass, while also preventing marks from appearing on the glass or the applied abrasion-resistant material layer. In some embodiments, both the first and second arms may comprise a body made primarily of abrasion-resistant material. For example, the insert may be composed of a material that does not possess the same abrasion-resistant properties as the first and second arms. The first and second arms may be secured to the body of the insert or to each other by an adhesive material or by connectors formed by mechanical fasteners or other connecting structures.

[0010] In some embodiments, the clamping structure of the insert incorporates at least one protrusion that contacts a second inner surface in the inner surface to retain the linear insert in the opening by creating friction between the at least one protrusion and the second inner surface. For example, the clamping structure may include a plurality of cylindrical extensions that increase friction to prevent displacement of the insert by vertical translation due to contact-based translational deformation. In another example, the clamping structure includes a plurality of spaced protrusions that increase the width of the insert to create a tighter fit between the insert and the inner surface. In yet another example, the clamping structure is a pair of lips extending along the length of the linear insert to form a pair of contact surfaces extending along the entire length of the U-shaped channel into which the lower portion is inserted. In some embodiments, fasteners such as screws or other attachment methods may be used for additional retaining portions at the front or rear end of the strap seal to secure the strap seal to the door.

[0011] In some embodiments, the upper portion of the body includes a head portion. In some embodiments, the cap is mechanically seated onto the head portion and secured in place by an adhesive layer or adhesive tape, or a combination thereof. In addition to the mechanical or adhesive-based securing aspects of the cap, the cap may also have an edge that engages with the head portion to secure the cap to an inner protrusion of the head portion.

[0012] In some embodiments, the cap includes at least two inner protrusions positioned to extend in opposite directions. The head portion of the strap seal may have a first lip extending toward a movable window when the linear insert is positioned in the opening, the first lip forming a slot for a first edge of the mechanically seated cap. The head portion may also have a first pair of flanges replacing the first lip forming the inner surface of the head portion or as extensions from the first lip. The head portion may also have a second pair of flanges extending from the outer surface of the head portion. The first pair of flanges may be structured to secure the first lip of the seated cap, which wraps around the head portion and extends inward toward the centerline of the seated cap. The second pair of flanges is structured to secure a second lip of the seated cap, which wraps around the head portion, extends inward toward the centerline of the seated cap, and protrudes in the opposite direction to the first lip. The lips of the seated cap may be incorporated into or extend from the inner protrusions of the cap.

[0013] In some embodiments, the door assembly includes an exterior door panel with a U-shaped channel. The U-shaped channel may incorporate an opening into which a strap-sealed structure incorporating any or all of the features described herein can be inserted. In some embodiments, the exterior door panel including the U-shaped channel is formed from a single continuous sheet of metal. For example, the U-shaped channel may be formed by three consecutive bends in the exterior door panel. A first bend may form a first opposing inner surface, a second bend may form a bottommost surface, and a third bend may form a second opposing inner surface of the U-shaped channel. The U-shaped channel may include a first inner wall near the window and a second outer wall near the outer surface of the exterior door panel. In some embodiments, the height of the first inner wall is shorter than that of the second outer wall.

[0014] In some embodiments, the door assembly can be manufactured by providing an external door panel including a U-shaped channel. A strap seal structure incorporating one or more features described herein mates with the U-shaped channel. The strap seal can be pressed into the U-shaped channel of the external door panel such that the clamping structure of the strap seal reaches at least a minimum depth within the U-shaped channel. A seat cap is secured to the top surface of the head portion of the strap seal. Attached Figure Description

[0015] The above and other objects and advantages of this disclosure will become apparent from the following specific embodiments taken in conjunction with the accompanying drawings, in which:

[0016] Figure 1 An example door assembly is shown, according to some disclosed embodiments, incorporating a thin strap seal assembly with a feature that increases vertical friction between the door assembly's U-shaped channel and the strap seal assembly;

[0017] Figure 2 An example door assembly with a combined strap sealing assembly according to some disclosed embodiments is shown, which uses an adhesive to mechanically secure a seat cap to the head portion of the strap sealing assembly.

[0018] Figure 3 An example vehicle assembly of a combined door according to some disclosed embodiments is shown, which utilizes a segmented seat cap to cover a strap sealing assembly inserted into a continuous U-shaped channel of the door, and the U-shaped channel is structured to have straight and curved portions;

[0019] Figure 4 An example method for manufacturing a door assembly with a combined strap sealing assembly is shown according to some of the disclosed embodiments; and

[0020] Figure 5 An example vehicle assembly including multiple door components is shown according to some disclosed embodiments. Detailed Implementation

[0021] This article provides a method and system for setting a thin outer harness seal having features capable of providing high-level retention of door assemblies.

[0022] Figure 1 A door assembly 100 is shown that incorporates a thin strap seal assembly with a feature that increases vertical friction between the door assembly’s U-shaped channel and the strap seal assembly.

[0023] The door assembly 100 includes a door frame 102 that houses a window adjacent to the inner door 104. When prompted by an actuator near a vertical surface defined by the inner door 104, the window can be vertically translating within the door frame 102. A seat cap 106 is the visible portion of a strap sealing assembly inserted into a U-shaped channel formed by the topmost portion of the outer door panel 108.

[0024] The strap seal assembly 110 includes a body having a lower portion that inserts into a U-shaped channel in an outer door panel 108. The strap seal assembly 110 is structured as a linear insert comprising two opposing outer sides extending the length of the U-shaped channel to form a seal for the door assembly 100. The lower portion is positioned within the U-shaped channel having a first outer wall higher than the second inner wall of the inner door 104. The body also has an upper portion including a head portion to which a seat cap 106 is attached. Extending from the head portion are flanges 112 and 114. Flange 112 of the strap seal assembly 110 forms a fastening fit around a first inner lip of the seat cap 106. Flange 114 of the strap seal assembly 110 faces the opposite direction to flange 112 and forms a fastening fit around a second inner lip of the seat cap 106. It should be noted that the flange features may have the same... Figure 1 The shapes or sizes depicted may differ from those described herein, and additional features may be incorporated to achieve retention of the covering layer. Additionally, the sealing lip is coupled to the linear insert and arranged to contact the movable window when the linear insert is positioned in the opening of the U-shaped channel. In some embodiments, the sealing lip includes a contact arm extending from the body of the strap sealing assembly 110 to the movable window.

[0025] The lower portion of the body has clamping features 116a and 116b. Clamping features 116a contact a first inner surface corresponding to a second, shorter, inner wall. Clamping features 116a are shown as finger-like extensions structured such that when these clamping features deform in response to contact or translation, they increase friction with the first inner surface. Clamping features 116b contact a second inner surface corresponding to a first, taller, outer wall. Clamping features 116b are shown as a plurality of protrusions that increase friction between the lower portion of the body and the second inner surface when the protrusions deform structurally based on translation or contact. A lower wall 118 forms the bottommost portion of a U-shaped channel. In some embodiments, the insertion depth is defined based on the relative distance between the lowest point on the strap sealing assembly 110 and the surface of the lower wall 118 facing the opening through the U-shaped channel. Sufficient insertion depth can vary with the amount of translation required to deform the clamping features 116a and 116b to ensure that the strap sealing assembly 110 remains within the U-shaped channel. Figure 1 The clamping feature depicted is an illustrative example of a single embodiment of a clamping feature that can be used in the strap sealing assembly 110 to secure the lower portion of the strap sealing assembly 110 within the depicted U-shaped channel. It should be noted that the clamping feature may have... Figure 1 The shape or size may differ from the shape or size depicted, and additional features may be incorporated to allow the lower portion of the strap sealing assembly 110 to remain at the insertion depth within the depicted U-shaped channel.

[0026] The strap seal assembly 110 is vertically inserted into the U-shaped channel of the exterior door panel 108. When the strap seal assembly 110 is inserted to the depth corresponding to the installation position in the U-shaped channel, the result is a thin strap seal assembly with a seat cap 106, which is the main visible component of the strap seal assembly 110. In some embodiments, a portion of the flange of the flange 114 may be visible below the lip of the seat cap 110.

[0027] Figure 1 The U-shaped channel depicted includes a pair of walls attached to the lower wall 118 at different heights. The walls are at different heights so that a portion of the body of the strap seal assembly 110 can be structured as part of a contact arm that forms a contact surface with a window to be positioned near the inner door 104. The inner wall near the inner door 104 is depicted as shorter than the outer wall, shown as being formed by a first bend in the material from the outer door panel 108. The shorter inner wall allows the pair of contact arms to extend from the body of the strap seal assembly 110, such that the head portion allows the thin strap seal assembly to be visible when the door assembly 100 is fully assembled. It should be noted that in Figure 1The relative height of the pair of walls forming the U-shaped channel is a single exemplary embodiment of the relative height of a pair of walls, which can be structured such that they are the same height or other relative heights. In some embodiments, the height of the walls can be structured in any way such that the visible portion of the strap seal assembly 110 can be considered a reduced profile or thin profile. The U-shaped channel is connected to the outer panel of the door assembly 100. The U-shaped channel includes an integrated U-shaped channel that forms a robust, lightweight structure to support the waistline seal. In some embodiments, the U-shaped channel is integrated into a vehicle assembly including four doors, wherein each of the four doors includes an outer panel with a U-shaped channel.

[0028] Figure 2 A door assembly 200 is shown, which uses adhesive to secure a seat cap to the head portion of a strap sealing assembly. According to some embodiments of this disclosure, the door assembly 200 can be used as a replacement for... Figure 1 The strap sealing assembly 110 in the door assembly 100, and / or may be combined with Figure 1 One or more features of the strap sealing assembly 110.

[0029] The door assembly 200 includes a strap sealing assembly 202. In some embodiments, the door assembly 200 will... Figure 1 At least one feature of the strap seal assembly 110 is incorporated into the strap seal assembly 202. The strap seal assembly 202 is structured as a linear insert comprising two opposing outer sides extending the length of a U-shaped channel to form a seal for the door assembly 200. The lower portion of the body of the strap seal assembly 202 is positioned within the U-shaped channel formed at the topmost portion of the outer door panel 204. The outer door panel 204 can be incorporated into... Figure 1 Any or all features of the exterior door panel 108. The strap sealing assembly 202 includes a body 224, which includes an upper portion having a head 210. Attached to the head 210 is a seat cap 212. The lower portion of the body is positioned within a U-shaped channel having a first outer wall that is higher than the second inner wall near the window 218.

[0030] The lower portion of the main body has clamping features 206a and 206b. Clamping feature 206a contacts the first inner surface corresponding to the second shorter inner wall. Clamping feature 206a is shown as a finger-like extension, structured such that when the clamping feature deforms in response to contact or translation, it increases friction with the first inner surface. Clamping feature 206b contacts the second inner surface corresponding to the first taller outer wall. Clamping feature 206b is shown as a plurality of protrusions that increase friction between the plurality of walls and the second inner surface when the protrusions deform structurally based on translation or contact. The lower wall 208 forms the bottom portion of the U-shaped channel. Sufficient insertion depth is defined based on the relative distance between the lowest point on the strap sealing assembly 202 and the surface of the lower wall 208 facing the opening through the U-shaped channel. Sufficient insertion depth can vary with the amount of translation required to deform the clamping features 206a and 206b to ensure that the strap sealing assembly 202 remains within the U-shaped channel. Figure 2 The clamping feature depicted is an illustrative example of a single embodiment of a clamping feature that can be utilized in the strap sealing assembly 202 to secure the lower portion of the strap sealing assembly 202 within the depicted U-shaped channel. It should be noted that the clamping feature may have... Figure 2 The shape or size may differ from the shape or size depicted, and additional features may be incorporated to allow the lower portion of the strap sealing assembly 202 to remain at the insertion depth within the depicted U-shaped channel.

[0031] The seated cap 212 can be combined Figure 1 At least one feature of the seat cap 106. An inner flange 214 is a feature of the head 210 extending toward the window 218. The inner flange 214 forms a tight-fitting channel with the head 210, thereby forming at least one side of the channel into which the lip of the seat cap 212 is positioned when installed in the strap seal assembly 210. An outer flange 216 is a feature of the head 210 extending toward the outer door panel 204. The outer flange 216 is structured to provide a second contact point for the head 210 for holding the seat cap 212 in a fixed position. In some embodiments, the inner flange 214 and the outer flange 216 are separate pieces not connected to the head 210, and the three components are made of different materials. In some embodiments, the inner flange 214 and the outer flange 216 are connected to the head 210 and are formed of the same material. An adhesive layer 220 provides a fixing surface for attaching the seat cap 212 to the head 210. In some embodiments, adhesive layer 220 is a strip of adhesive material arranged axially along the length of the strap sealing assembly 202. In some embodiments, adhesive layer 220 is used in conjunction with or alternatively with fasteners. In some embodiments, adhesive layer 220 is used with... Figure 1 Flanges 112 and 114 are used together.

[0032] Extending from the body 224 are a primary contact arm 222, a secondary contact arm 226, or some combination thereof. A sealing lip is coupled to the linear insert and arranged to contact the movable window when the linear insert is positioned in the opening of the U-shaped channel. In some embodiments, the sealing lip includes a contact arm extending from the body of the strap sealing assembly 202 to the movable window. For example, the primary contact arm 222 may include an extension coupled to the body 224 that engages with the secondary contact arm 226. In some embodiments, the secondary contact arm 226 may include an extension coupled to the body 224, wherein the primary contact arm 222 includes a separate extension attached to the secondary contact arm 226, such as... Figure 2 As shown. In some embodiments, both the primary contact arm 222 and the secondary contact arm 226 may extend from and be connected to the body 224. In some embodiments, both the primary contact arm 222 and the secondary contact arm 226 are formed of a portion of the material connected to the body 224. In some embodiments, either or both of the primary contact arm 222 and the secondary contact arm 226 are formed of a portion of the material attached to a portion of the material including the body 224. For example, as... Figure 2 As shown, the primary contact arm 222 can be formed independently of the secondary contact arm 226, which is depicted as an extension formed of material connected to the body 224. The material comprising the structure of the primary contact arm 222 can be attached to the secondary contact arm 226 by adhesives or mechanical means (e.g., fixing protrusions or fasteners), such as... Figure 2 As shown, or attached to the main body 224.

[0033] Region 228 provides an exemplary example of an element that can be incorporated into the strap sealing assembly 202 in the body 224. For example, region 228 summarizes the body 224 such that the lower portion of the body 224 having clamping features 206a and 206b accommodates a U-shaped channel formed of material connected to the outer door panel 204, such as... Figure 2 As shown. Additionally, each of the primary contact arm 222 and the secondary contact arm 226 in Figure 2 The image shows a feature portion covered by region 228, and Figure 2 The embodiment shown is an example of a single embodiment of the embodiments described in this disclosure. Region 228 further encompasses a neck portion connected to the head 210, which may have a relative width or height compared to the U-shaped channel, wherein the lower portion of the body is inserted to achieve a thinner or taller strap seal structure covered by the seated cap 212. Figure 2As shown, the neck portion covered by region 228 is intended as a non-limiting illustrative example of the relative dimensions of the neck portion, body 224, head 210, U-shaped channel, and lower portion of body 224. Each of the listed elements can be structured such that its dimensions differ from those of other elements. Figure 2 The dimensions are depicted so that different strap sealing assemblies with different profiles can be used for various door assemblies.

[0034] In some embodiments, the body 224, primary contact arm 222, and secondary contact arm 226 are all structured from the same material. In some embodiments, the body 224, primary contact arm 222, and secondary contact arm 226 are made of separate materials. In some embodiments, the primary contact arm 222 and secondary contact arm 226 include an abrasion-resistant material that reduces drag / friction on the contact surfaces of the window and also prevents marks from appearing on the window, which is a coating or a fixed layer of material. The abrasion-resistant material is structured to prevent water from sliding down from the window 218 into the door assembly. The primary contact arm 222 forms a first contact surface with the window 218. As the window 218 moves vertically upward, the primary contact arm 222 is dragged upward, and the secondary contact arm 226 is pulled toward the window 218, thereby forming a second contact surface. The secondary contact arm 226 may include shock-absorbing features for rotating the door by supporting the window 218, such that it does not contact the metal from the door assembly. Figure 2 The document also shows an internal strap seal 230, which is fixed to a support structure on the inside of the door and forms a seal on the opposite side of the window.

[0035] The strap seal assembly 202 is vertically inserted into the U-shaped channel of the outer door panel 204. When the strap seal assembly 202 is inserted to the depth corresponding to the installation position in the U-shaped channel, a thin strap seal assembly with a seat cap 212, which is the main visible component of the strap seal assembly 202, is obtained. In some embodiments, a portion of the outer flange 216 may be visible below the lip of the seat cap 212.

[0036] Figure 2 The U-shaped channel depicted includes a pair of walls attached to the lower wall 208 at different heights. The walls are at different heights so that a portion of the body 224 of the strap seal assembly 202 can be structured as part of a primary contact arm 222 and a secondary contact arm 226, which form a contact surface with the window 218. The inner wall near the window 218 is depicted as shorter than the outer wall, shown as being formed by a first bend from the material of the outer door panel 204. The shorter inner wall allows the pair of contact arms to extend from the body 224 of the strap seal assembly 202, so that the head 210 allows the thin strap seal assembly to be visible when the door assembly 200 is fully assembled. It should be noted that in Figure 2 The relative height of the pair of walls forming the U-shaped channel is a single exemplary embodiment of the relative height of a pair of walls, which can be structured such that they are the same height or other relative heights. In some embodiments, the height of the walls can be structured in any way such that the visible portion of the strap seal assembly 202 can be considered a reduced profile or thinner profile. The U-shaped channel is connected to the outer panel of the door assembly 200. The U-shaped channel includes an integrated U-shaped channel that forms a robust, lightweight structure to support the waistline seal.

[0037] Figure 3 A vehicle 300 is shown including a door utilizing a segmented U-shaped channel, the segmented U-shaped channel comprising both straight and curved sections, covered by a seat cap of a head portion of a strap sealing assembly attached to the U-shaped channel inserted into the door. According to some embodiments of this disclosure, the vehicle 300 can be combined with... Figure 1 Door assembly 100 and / or Figure 2 The feature of the door assembly 200.

[0038] Vehicle 300 includes a chassis assembly, a powertrain assembly, and a body 302. A door 304 is connected to the body 302. Door 304 includes features such as hinges, handles, exterior panels, and a window assembly 306. The window assembly 306 may include... Figure 1 and Figure 2 Any or all of the elements depicted herein, such that door 304 includes components made of Figure 1 and Figure 2 The belt-sealing assembly depicted forms a seal configured to reduce or prevent fluid from entering the door 304 through the window 308. The window 308 is arranged to vertically translate within the door 304. The window assembly 306 is formed having a first straight portion defining a body that is at least a portion of the width of the door 304, but not the entire length of the door 304. In some embodiments, the first straight portion is the entire width of the door 304. The window assembly 306 also has a vertically upward curved portion positioned behind the first straight portion relative to the front of the body 302. Extending vertically from the vertically upward curved portion is a third vertical portion defining a rear pillar for the window assembly 306.

[0039] Window assembly 306 also has a straight portion 310, a curved portion 312, and a vertical portion 314 of the U-shaped channel. The strap sealing assembly (e.g., Figure 1 Belt sealing assembly 110 Figure 2 The strap sealing assembly 202 or any combination thereof is inserted into the U-shaped channel formed by portions 310, 312, and 314. In some embodiments, the strap sealing assembly is capped (e.g., Figure 1 Seating cap 106 or Figure 2The seat cap 212) covers the area and has straight sections, upwardly curved sections, and vertical sections, which may be continuous or discrete and correspond to the shape of the U-shaped channel. In some embodiments, the strap sealing assembly in sections 310, 312, and 314 is a continuous strap sealing assembly.

[0040] The U-shaped channel of window assembly 308 can be formed from the material of the outer panel of door 304 by any process known to those skilled in the art. As shown in window assembly 308, some windows and doors have curves at least in part based on the design of the vehicle body or corresponding to a style preference of the vehicle body. When attempting to form a U-shaped channel corresponding to a style preference of the vehicle body, the U-shaped channel of window assembly 308 can be formed from the material of the outer panel of door 304 by any process known to those skilled in the art. Figure 3 When constructing a continuous U-shaped channel with straight, curved, and vertical sections 310, 312, and 314 as depicted, manufacturers may face difficulties in forming the curved sections of the U-shaped channel from the same metal sheet used to form the straight and vertical sections. The metal sheet can be bound, folded, or wrinkled in response to input to form the curved sections of the U-shaped channel. To address these issues, each portion of the U-shaped channel can be formed in sequential steps. Alternatively, the curved sections of the U-shaped channel can be formed using separate manufacturing steps. For example, a section or all of the curved section can be formed independently from a metal sheet or a different material than the metal sheet, which includes an outer door panel used to form the straight and vertical sections of the U-shaped channel.

[0041] In some embodiments, the separately formed curved portions can be fixed (e.g., attached or installed by mechanical means or adhesives or a combination thereof) to the outer door panel and positioned such that the U-shaped channel is connected between the straight, curved, and vertical portions. In some embodiments, the elements of the curved portions can be formed from separate metal sheets or materials. For example, the inner and / or bottom walls of the U-shaped channel can be formed from separate metal sheets or materials. The inner and / or bottom walls can be fixed to an outer wall, which can be connected to the outer door panel used to form the straight and vertical portions of the U-shaped channel. Each of the straight, curved, and vertical portions of the U-shaped channel can include a corresponding start edge and end edge. When arranged in a door assembly, the end edge of the portion is aligned with the start edge of the connecting portion. For example, the end edge of the straight portion can be aligned with the start edge of the curved portion. In some embodiments, the end edge of the curved portion can be aligned with the start edge of the vertical portion.

[0042] Figure 4 A method 400 for manufacturing a door assembly with a combined strap seal assembly is shown. According to some embodiments of this disclosure, method 400 can be combined with or used in manufacturing... Figure 1 Door assembly 100 Figure 2 Door components 200 and / or Figure 3 All aspects of the vehicle 300.

[0043] At 402, an exterior door panel including a U-shaped passage is provided (e.g., Figure 1 108, exterior door panels Figure 2 The exterior door panel 204 or corresponding Figure 3 The outer door panel of the outer surface of door 304). At 404, a window is provided near the outer door panel (e.g., Figure 2 Window 218 or Figure 3 Window 308). At 406, a strap sealing assembly is provided for insertion into a U-shaped channel in the exterior door panel (e.g., Figure 1 Belt sealing assembly 110 Figure 2 (A strap seal assembly 202 or any combination thereof combining their features). At 408, the strap seal assembly is pressed into the U-shaped channel. In some embodiments, the strap seal assembly has a specific minimum depth for insertion to achieve a frictional fit, such that the pull-out force of the strap seal is above a minimum. In some embodiments, the minimum depth varies with clamping structures on the surface of the strap seal assembly positioned inside the U-shaped channel. When the strap seal assembly is inserted to the minimum depth, a portion of the strap seal assembly contacts the window provided at 404 via a contact surface, which forms a seal to prevent fluid from entering the door assembly in which the window is arranged close to the exterior door panel, such as... Figure 1 and Figure 2 As shown.

[0044] In some embodiments, at 410, a seat cap is provided, and this seat cap is structured to enclose the protrusion of the strap sealing assembly without contacting the window. For example, the seat cap could be... Figure 1 Seating cap 106 Figure 2 Seating cap 212, Figure 3 The protrusion may be any or all of the straight portion 310, the curved portion 312, and the vertical portion 314, or any combination thereof. Figure 1 The head of the strap sealing assembly 110, Figure 2 The head 210 or any combination thereof. In some embodiments, at 412, the seat cap is secured to a protrusion of the strap seal structure. For example, the seat cap can be secured by adhesive, corresponding flanges on both the seat cap and the protrusion, fasteners, or any combination thereof. In some embodiments, the seat cap can be secured to the strap seal before delivery to the door for assembly.

[0045] Figure 5 A vehicle 500 including multiple door assemblies is shown. According to some embodiments of this disclosure, the vehicle 500 can be combined with… Figure 1 Door assembly 100 Figure 2 200 door components Figure 3Vehicle 300, and / or can be used Figure 4 Method 400 manufacturing.

[0046] Vehicle 500 includes a body 502. Attached to the body 502 are door assemblies 504a and 504b. In some embodiments, the body 502 has two additional door assemblies 504c and 504d positioned rearward of the door assemblies 504a and 504b. Each of the door assemblies 504a-504d includes an exterior panel 506a-506d, which is respectively adjacent to each of the windows 510a-510d. Each of the exterior panels 506a-506d can be combined with... Figure 1 External door panels 108 and / or Figure 3 Any or all features of all doors 304. Each of the external panels 504a-504d is a strap seal 508a-508d. Each strap seal 508a-508d can be combined with Figure 1 The strap sealing assembly 110 and / or Figure 2 Any or all of the features of the strap sealing assembly 202.

[0047] Each of the door assemblies 504c and 504d has an outer panel 506c and 506d, which respectively includes straight portions 512c and 512d. Additionally, the outer panels 506c and 506d each include curved portions 514c and 514d. A strap seal 508c is inserted into each of the straight portions 512c and 514c. Similarly, a strap seal 508d is inserted into each of the straight portions 512d and 512d. Each of the straight portions and curved portions can be respectively made of… Figure 3 The upright seat cover portion 310 and the curved seat cover portion 312 are indicated.

[0048] The systems and processes discussed above are intended to be illustrative and not restrictive. Those skilled in the art will recognize that the actions of the processes discussed herein can be omitted, modified, combined, and / or rearranged, and any additional actions can be performed without departing from the scope of this disclosure. More generally, the above disclosure is intended to be exemplary and not restrictive. Only the appended claims are intended to set the limits regarding the scope of this disclosure. Furthermore, it should be noted that the features and limitations described in any embodiment are applicable to any other embodiment herein, and flowcharts or examples associated with one embodiment can be combined with any other embodiment in a suitable manner, performed in a different order, or in parallel. Moreover, the systems and methods described herein are operable in real time. It should also be noted that the above systems and / or methods can be applied to or used according to other systems and / or methods.

[0049] While some parts of this disclosure may refer to "convention" or examples, any such references are merely for providing context to this disclosure and do not constitute any admission that constitutes prior art.

Claims

1. A strap sealing structure, the strap sealing structure comprising: - A linear insert comprising two opposing outer surfaces, the linear insert being configured to fit into an opening of a channel having two opposing inner surfaces, wherein: a first outer surface of the linear insert includes a clamping structure arranged such that when the linear insert is positioned in the opening, the clamping structure engages with a first inner surface of the inner surfaces to retain the linear insert in the opening; and - A sealing lip, the sealing lip being coupled to the linear insert and arranged to contact the movable window when the linear insert is positioned in the opening, the sealing lip comprising: --Primary contact arm, the primary contact arm extending from the body of the linear insert, and --Secondary contact arm, which extends from the portion of the body from which the primary contact arm extends, wherein the secondary contact arm extends along the outer surface of the channel.

2. The strap sealing structure of claim 1, wherein the clamping structure includes at least one protrusion configured to contact the first inner surface of the inner surface to retain the linear insert in the opening by forming friction between the at least one protrusion and the first inner surface of the inner surface.

3. The strap sealing structure of claim 2, wherein the clamping structure further comprises at least one protrusion configured to contact a second inner surface of the inner surface to retain the linear insert in the opening by forming friction between the at least one protrusion and the second inner surface of the inner surface.

4. The strap sealing structure according to claim 1, wherein: The main body includes a lower portion and an upper portion, the lower portion including the linear insert; When the linear insert is positioned in the opening, the upper portion of the body extends above the opening; and The sealing lip includes a first contact surface, and the primary contact arm connects the first contact surface to the upper portion of the body.

5. The strap sealing structure of claim 4, wherein the sealing lip further includes a second contact surface, and the secondary contact arm connects the second contact surface to the upper portion of the body.

6. The strap sealing structure according to claim 5, wherein the first contact surface and the second contact surface comprise a wear-resistant material layer to prevent marks from appearing on the glass window.

7. The strap sealing structure according to claim 5, wherein the sealing lip includes a central body connected at one end to the upper portion of the body and at the opposite end to the primary contact arm and the secondary contact arm.

8. The strap sealing structure according to claim 1, wherein the upper portion of the body includes a head portion.

9. The strap sealing structure according to claim 8 further includes a cap mechanically seated on the head portion.

10. The strap sealing structure according to claim 9, wherein the cap is secured in place by an adhesive.

11. The strap sealing structure of claim 9, wherein the cap includes an edge that engages with the head portion to secure the cap to an inner protrusion of the head portion.

12. The strap sealing structure of claim 9, wherein the head portion further includes a first lip extending toward the movable window when the linear insert is positioned in the opening, wherein the first lip forms a slot for a first edge of the cap.

13. The strap sealing structure of claim 9, wherein the head portion further comprises a first pair of flanges extending from the inner surface of the head portion and a second pair of flanges extending from the outer surface of the head portion, wherein: The first pair of flanges are structured to secure the first lip of the cap, the first lip wrapping around the head portion and extending inward toward the centerline of the cap; and The second pair of flanges is structured to secure the second lip of the cap, which wraps around the head portion, extends inward toward the centerline of the cap, and protrudes in the opposite direction to the first lip.

14. A door assembly, the door assembly comprising: An exterior door panel, the exterior door panel including a U-shaped channel, the exterior door panel including the U-shaped channel being formed from a single continuous metal sheet; The cable belt sealing structure includes: - A linear insert having two opposing outer sides, the linear insert being disposed in a U-shaped channel having two opposing inner surfaces, wherein: a first outer side of the linear insert includes a clamping structure arranged such that when the linear insert is positioned in the U-shaped channel, the clamping structure engages with a first inner surface of the inner surfaces to retain the linear insert in the U-shaped channel; and - A sealing lip, the sealing lip being coupled to the linear insert and arranged to contact the movable window when the linear insert is positioned in the U-shaped channel, and the sealing lip comprising: --Primary contact arm, the primary contact arm extending from the body of the linear insert, and --Secondary contact arm, which extends from the portion of the body from which the primary contact arm extends, wherein the secondary contact arm extends along the outer surface of the U-shaped channel.

15. The door assembly of claim 14, wherein the U-shaped channel is formed by three consecutive bends in the outer door panel, wherein a first bend forms a first opposing inner surface, a second bend forms a bottommost surface, and a third bend forms a second opposing inner surface of the U-shaped channel.

16. The door assembly of claim 14, wherein the U-shaped channel includes a first inner wall near the window and a second outer wall near the outer surface of the outer door panel, and wherein the height of the first inner wall is shorter than that of the second outer wall.

17. The door assembly of claim 14, wherein the clamping structure includes at least one protrusion configured to contact the first inner surface of the inner surface to retain the linear insert in the U-shaped channel by forming friction between the at least one protrusion and the first inner surface of the inner surface, such that the at least one protrusion is mechanically deformable when mounted in the U-shaped channel.

18. The door assembly of claim 14, wherein the U-shaped channel includes a straight portion and a curved portion, wherein the straight portion is formed by the outer door panel, and wherein the curved portion is independently formed and mounted to the outer door panel such that the curved portion is aligned with the straight portion.

19. A method for manufacturing a vehicle door assembly, the method comprising: An exterior door panel including a U-shaped channel is provided, wherein the exterior door panel including the U-shaped channel is formed from a single continuous metal sheet; A cable belt sealing structure is provided, the cable belt sealing structure comprising: - A linear insert having two opposing outer sides, the linear insert being configured to be mounted in a U-shaped channel having two opposing inner surfaces, wherein: a first outer side of the outer sides of the linear insert includes a clamping structure arranged such that when the linear insert is positioned in the U-shaped channel, the clamping structure engages with a first inner surface of the inner surfaces to retain the linear insert in the U-shaped channel; and - A sealing lip, the sealing lip being coupled to the linear insert and arranged to contact the movable window when the linear insert is positioned in the U-shaped channel, and the sealing lip comprising: --Primary contact arm, the primary contact arm extending from the body of the linear insert, and --Secondary contact arm, the secondary contact arm extending from the portion of the body from which the primary contact arm extends, wherein the secondary contact arm extends along the outer surface of the U-shaped channel; The strap sealing structure is pressed into the U-shaped channel of the outer door panel, such that the clamping structure reaches at least a minimum depth within the U-shaped channel; and Secure the seat cap to the top surface of the head portion of the strap sealing structure.

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