Integrated hot bending and injection molding of extruded profile parts without reinforcing carrier

Abstract

A method of manufacturing a vehicle component is disclosed, including providing a body having an extruded profile formed at least in part from a material and a recess formed through a portion of the body. The method includes placing the body having the extruded profile with the recess formed therein into a mold cavity. While in the mold cavity, the process includes (i) bending the body from a first straight configuration to a second curved configuration at a temperature below a melting temperature of the material, and (ii) introducing a filler material to form (e.g., mold) a filler member into the recess of the curved body, the filler member formed from a same or different material as the body material that will bond with the body material.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to U.S. Provisional Application No. 63 / 609,532, filed December 13, 2023, the entire disclosure of which is expressly incorporated herein by reference.

[0003] This disclosure relates to a manufactured vehicle component, and more specifically, to an extruded profile component, such as a window sealing assembly for an associated vehicle. More specifically, this disclosure relates to an improved method for manufacturing the vehicle component. Background Technology

[0004] There is currently a type such as Figure 1 The method for manufacturing a vehicle component V is generally illustrated. Specifically, the manufacturing of the vehicle component begins with the extrusion of a profile body B. Typically, a notch or groove N extends partially through the cross-section of the body B. Opposite ends E1 and E2 are linearly or longitudinally spaced apart from each other, and the notch N is disposed between the opposite ends. In particular, a portion of the body B between ends E1 and E2 undergoes a bending operation, and the notch N is located approximately at the mid-span or middle length of the bend in the body. For example, typically... Figure 1 The straight body B shown on the left side is bent into Figure 1 The left-middle section shows a curved or arc-shaped configuration B'. The curved configuration B' can be achieved using conventional bending operations. In one example, the body B is subjected to a heating operation to an elevated temperature to soften it, allowing opposite ends E1, E2 to approach each other, and the notch N is located at the apex of the included obtuse angle (i.e., the angle between 90° and 180°). Once bent to the desired angle, the body B' remains at the desired angle until the material of the body cools, solidifies, or sets to maintain the desired bending angle.

[0005] Subsequently, the curved body B' is introduced into a mold (not shown) and subjected to an injection molding or overmolding step, wherein filler material F is introduced or injected into the cavity of the mold. A desired amount of filler material F is introduced into the mold and guided into a notch N, thereby forming a filler member FM that fills the notch N. The filler member FM may also include a straight portion that extends at least partially into the curved body B' in the opposite longitudinal direction of the notch. The filler material F is at least partially cured, i.e., to the extent that the curved body B' and the filler member FM maintain the integrity of the curved configuration / structure to form a desired curved shape that matches the contour of a sloping or curved area at the top of, for example, a vehicle door or a vehicle door opening.

[0006] Despite its commercial use, there is always a search for improvements over this existing technological approach in terms of efficiency, manufacturing speed, and cost. Therefore, a solution is desired that provides functionally compatible components and addresses one or more of these shortcomings, while still retaining other advantageous features and benefits. Summary of the Invention

[0007] This disclosure provides integrated hot bending and forming of extruded profiles without reinforcing carriers for the body.

[0008] A method of manufacturing a vehicle component includes providing a body having an extruded profile at least partially formed of material and a notch formed through a portion of the body. The method includes placing the body, with the extruded profile having the notch formed therein, into a mold cavity. While in the mold cavity, the process includes (i) bending the body from a first straight configuration to a second bent configuration at a temperature below the melting temperature of the material, and (ii) introducing a filler material to form (e.g., mold) a filler member into the notch of the bent body, the filler member being formed of a material that is the same as or different from the body material, the filler material being bonded to the body material.

[0009] The bending and forming steps are performed at least partially simultaneously.

[0010] The provision process includes supplying the body without a reinforcing carrier.

[0011] The steps include initially extruding the body into the desired profile.

[0012] The bending step includes orienting the body such that the notch is located within an acute or obtuse angle between the first and second ends of the bent body.

[0013] The body orientation step positions the notch in the obtuse angle between the first and second ends of the curved body.

[0014] The body bending step includes moving at least portions of the first and second sidewalls of the notch closer to each other.

[0015] The method also includes at least partially curing the filling component while the body is in the mold cavity to keep the body in the second bending configuration.

[0016] The method also includes removing the bent body with at least partially cured filler from the mold cavity after a partial curing step.

[0017] The method also includes using the same material as the body material for the infill components.

[0018] The method also includes using the same material as the body material for the infill component, and the same material for the infill component and the body has different hardness.

[0019] The method also includes forming a filler component using a filler component material different from the body material, and the body material and the filler component material forming an integral structure when cured together.

[0020] Methods for manufacturing vehicle components include manufacturing the top of a window sealing assembly for an associated vehicle.

[0021] The main benefit of this disclosure is the improvement in process time for manufacturing / producing vehicle parts.

[0022] Another advantage of this disclosure is that it reduces the difficulty of introducing the body into the mold cavity.

[0023] Another benefit is associated with the ability to achieve smaller bending / curvature radii in the final manufactured parts.

[0024] Another advantage is the cost reduction associated with reducing the number of individual operations in the manufacturing process.

[0025] Other benefits and advantages of this disclosure will become more apparent upon reading and understanding the following detailed description. Attached Figure Description

[0026] Figure 1 It is a schematic representation of existing technical methods for forming curved vehicle components.

[0027] Figure 2 This is a view of a vehicle component, such as a door sealing assembly, which includes a curved area along the top of the component.

[0028] Figure 3 yes Figure 2 An enlarged view of a vehicle component, with particular emphasis on the filling member formed in a recess in a body having an extruded profile.

[0029] Figure 4 This is a schematic representation of the method for forming curved vehicle components. Detailed Implementation

[0030] The following description, with reference to the accompanying drawings, is provided to aid in a full understanding of one or more versions or embodiments of this disclosure as defined by the claims and their equivalents. It includes various specific details to aid understanding, but these details should be considered exemplary only. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the various embodiments described herein without departing from the scope and spirit of this disclosure. The various exemplary embodiments of this disclosure are not limited to the specific details of different variations or embodiments and should be construed as including all changes and / or equivalents or substitutions within the spirit and technical scope of the appended claims. In describing the drawings, similar reference numerals are used wherever possible to denote similar elements.

[0031] The terms “comprising” or “may include” as used in this disclosure mean the presence of the disclosed corresponding functions, operations, elements, etc., and do not limit the addition of one or more additional functions, operations, elements, etc. Furthermore, it should be understood that the terms “include,” “including,” “have,” or “having” as used in this disclosure are intended to indicate the presence of the components, features, numbers, steps, operations, elements, parts, or combinations thereof described in the specification, and do not exclude the presence or addition of one or more other features, numbers, steps, operations, elements, parts, or combinations thereof.

[0032] As used in this disclosure, the term "or" or "at least one of A and / or B" includes any and all combinations thereof with the words listed. For example, "A or B" or "at least one of A and / or B" means including A, including B, or including both A and B.

[0033] Although terms such as “first” and “second” used in this disclosure may modify various elements of different exemplary embodiments, these terms do not limit the corresponding elements. For example, these terms do not limit the order and / or importance of the corresponding elements, nor do they exclude additional elements (e.g., third, fourth, etc.). These terms can be used to distinguish one element from another. For example, both “first mechanical device” and “second mechanical device” refer to mechanical devices, and may refer to mechanical devices of different types or the same type. For example, without departing from the scope of the various exemplary versions or embodiments of this disclosure, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element.

[0034] It should be understood that when an element is referred to as being "connected" or "coupled" to another element, the element may be directly connected or coupled to the other element, and there may be an intermediate element between the two elements. Conversely, it should be understood that when an element is referred to as being "directly connected" or "directly coupled" to another element, there is no intermediate element between the two elements.

[0035] The terminology used in the various exemplary versions or embodiments of this disclosure is for the purpose of describing a particular exemplary version or embodiment only and is not intended to limit the various exemplary versions or embodiments of this disclosure. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise. The use or absence of further adjectives such as “generally,” “substantially,” “about,” or “approximately” in the description or claims of dimensions, temperatures, ranges, times, relationships (e.g., “vertical,” “parallel”) is intended to cover specific dimensions, temperatures, ranges, times, relationships, etc., and a range of equivalents (functions, methods, or results), and is intended only to be limited by the teachings of the prior art.

[0036] The terminology used in the various exemplary versions or embodiments of this disclosure is for the purpose of describing a particular exemplary version or embodiment only and is not intended to limit the various exemplary versions or embodiments of this disclosure. As used herein, the singular form is intended to include the plural form unless the context expressly indicates otherwise.

[0037] Unless otherwise defined, all terms used herein (including technical or scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art. Terms as defined in commonly used dictionaries shall be interpreted as having the same meaning as in the context of the relevant art, and shall not be construed as having an inconsistent or exaggerated meaning unless explicitly defined in various exemplary embodiments.

[0038] refer to Figure 2-4 The illustration shows a vehicle component 100 formed from an unsupported extruded profile body, having a curved region in a portion thereof. More specifically, and without limiting this disclosure, "unsupported extruded profile" refers to any unsupported extruded component that requires bending to a small radius and overmolding, and that the component can be used in any location on a vehicle. For example, this process can be applied to a wide variety of sealing assemblies, i.e., sealing strip assemblies including rigid polymer gripping areas (e.g., rigid polypropylene (PP) or thermoplastic vulcanizate (TPV)—the more rigid polymer gripping portion of the sealing assembly, and which requires a heat bending step to configure the component), which are typically associated with outer belt seal assemblies, inner belt seal assemblies, etc. Similarly, this process can be applied to hood seals that include rigid gripping areas.

[0039] In this particular example, exemplary vehicle component 100 is a vehicle sealing assembly or glass channel sealing assembly associated with a vehicle door (e.g., a front door—not shown). Sealing assembly 100 includes first and second generally vertical portions 102, 104 extending in a straight line at the front and rear ends of the door. First ends or upper ends 106, 108 are connected to a header portion 120. In this particular example, the header portion 120 extends in front of the front vertical portion 102 in the area indicated by reference numeral 122, and also extends behind the rear vertical portion 104 in the area indicated by reference numeral 124. The vertical portions 102, 104 and the central portion 126 of the header portion 120 located between the vertical portions are shaped as part of the manufacturing process to include one or more sealing lips oriented for abutting and sealing engagement along the peripheral edge of a door / window (not shown) that selectively rises and falls relative to sealing assembly 100.

[0040] Selected areas of the sealing assembly 100 include molded structures / parts for interconnecting the sealing assemblies and / or forming a fitted, sealing engagement with adjacent areas of the vehicle. For example, and without unduly limiting this disclosure, these molded portions include interconnecting molded corners 130, 132 connecting the respective upper vertical portions 102, 104 to the top 120. The molded portions also include sealing interface regions 134 and 136 at the front and rear ends of the top 120.

[0041] It is worth noting that the central portion 126 of the top 120 is bent along at least a portion of its length between corners 130 and 132. This disclosure does not provide a separate bending operation or the separate insertion of the bent body into the mold cavity to enclose the molding filler component (such as...) in the recess of the bent body. Figure 1 As described above, this disclosure achieves the formation of a filling component in a mold cavity through hot bending and injection molding. Figure 2-4 The configuration shown. It can be understood that the linear, unsupported (i.e., without reinforcing carrier) extruded profile body 140 includes a notch 142 formed therein. The notched body 140 is inserted into a mold cavity indicated by dashed lines and reference numeral 144, wherein hot bending 146 of the body and injection molding 148 of the filler material to form a filler member 150 are completed to provide a curved vehicle component 160 including the injection-molded filler member 150.

[0042] Combining these two method steps 146 and 148 in mold cavity 144 provides superior performance. Figure 1 The existing manufacturing methods shown have many advantages. For example, Figure 4 This method is an improvement on the existing arrangement because loading the straight body 140 into the mold cavity is easier than loading the bent body. Furthermore, since both the hot bending step 146 and the injection molding step 148 are performed in the mold cavity 144, processing time is improved. It eliminates the need for... Figure 1 Instead of waiting for the hot-bent body to at least partially cure before transferring it to a mold cavity for subsequent injection molding / overmolding of the filler component, the hot bending 146 and injection molding / overmolding 148 are performed in a single mold cavity 144 to form a curved vehicle component 160 including an overmolded filler component 150. This combined hot bending and overmolding process for unsupported extruded profiles advantageously results in a smaller radius than existing arrangements that attempt to avoid molding or hot bending.

[0043] The hot bending 146 and forming 148 steps are performed at least partially simultaneously. The extruded, notched, straight body 140 can be manufactured shortly before the combined hot bending 146 and injection molding 148 steps, or the body 140 can be manufactured separately long before these additional steps performed in the mold cavity 144. Figure 2-4Equally evident is that the body 140 is oriented such that the notch 142 lies within an acute or obtuse angle between the first and second ends of the resulting bent body. Upon bending, the sidewalls of the notch are angled together and move closer to each other.

[0044] Preferably, the filler material injection-molded / overmolded into the notch 142 of the body 140 is preferably the same as the general material of the portion of the body in which the notch is formed. In this way, the filler member 150 is firmly bonded to the remainder of the body and helps maintain the flexural configuration of the heat-bent body. That is, the notch 142 facilitates heat bending 146, and once the filler material has at least partially cured, the filler member 150 helps maintain the flexural configuration of the vehicle component 160. For example, thermoplastic elastomers (TPE) or thermoplastic vulcanizates (TPV) are commonly used materials in such vehicle components, although other materials may be used without departing from the scope and intent of this disclosure, and reference to such commonly used materials should not be considered limiting. While using the same general material, it should also be understood that one or more desired physical properties of the same material can be achieved, for example, if different hardnesses are desired between the body and the filler member 150.

[0045] This written description uses examples to illustrate this disclosure, including best practices, and also enables any person skilled in the art to make and use this disclosure. Other examples that may occur to a person skilled in the art are intended to fall within the scope of the invention if they have structural elements that are not different from the same concept or the literal language of the claims, or if they comprise equivalent structural elements that are not substantially different from the same concept or the literal language of the claims. Furthermore, this disclosure is intended to seek protection for combinations of components and / or steps initially presented for examination, as well as combinations of claims, and, during the examination process, to seek potential protection for other combinations of components and / or steps, as well as combinations of claims.

[0046] While specific advantages have been listed above, various embodiments may include some, all, or none of these listed advantages. Although exemplary embodiments are shown in the accompanying drawings and description herein, the principles of this disclosure can be implemented using any number of techniques, whether currently known or not. Furthermore, the operation of the systems and devices disclosed herein may be performed by more, fewer, or other components, and the methods described herein may include more, fewer, or other steps. Moreover, the steps may be performed in any suitable order.

[0047] In order to assist the Patent Office and any reader of this application and any resulting patent in interpreting the appended claims, the applicant does not intend any appended claim or claim element to invoke 35 USC 112(f) unless the words “means for…” or “steps for…” are expressly used in a particular claim.

Claims

1. A method for manufacturing a vehicle component, comprising: A body is provided, the body having at least a portion of an extruded profile formed of material and a notch formed through a portion of the body; A body with an extruded profile is placed into a mold cavity, the extruded profile having a notch formed therein; and In the mold cavity, (i) the body is bent from a first straight configuration to a second bent configuration at a temperature below the melting temperature of the material, and (ii) a filler member is formed into the recess of the bent body, the filler member being formed of a material that is the same as or different from the body material, which will be bonded to the body material.

2. The method according to claim 1, wherein, The bending and forming steps are performed at least partially simultaneously.

3. The method according to claim 1, wherein, The provision process includes supplying the body without a reinforcing carrier.

4. The method according to claim 1, wherein, The steps include initially extruding the body into the desired profile.

5. The method according to claim 4, wherein, The extrusion step does not include the reinforcing carrier.

6. The method according to claim 1, wherein, The bending step includes orienting the body such that the notch is located within an acute or obtuse angle between the first and second ends of the bent body.

7. The method according to claim 6, wherein, The body orientation step positions the notch in the obtuse angle between the first and second ends of the curved body.

8. The method according to claim 1, wherein, The body bending step includes moving at least portions of the first and second sidewalls of the notch closer to each other.

9. The method of claim 1, further comprising, while the body is located in the mold cavity, at least partially curing the filling member to maintain the body in the second curved configuration.

10. The method of claim 9, further comprising, after the partial curing step, removing the bent body with at least partially cured filler from the mold cavity.

11. The method of claim 1, further comprising using the same material as the body material for the filling member.

12. The method of claim 1, further comprising using the same material as the body material for the filling member, and the same material for the filling member and the body having different hardness.

13. The method of claim 1, further comprising forming a filler member with a filler member material different from the body material, wherein the body material and the filler member material form an integral structure when cured together.

14. The method according to any one of claims 1-13, wherein, Methods for manufacturing vehicle components include manufacturing the top of a window sealing assembly for an associated vehicle.

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