Seal assembly

Abstract

A seal assembly is adapted to be coupled to a vehicle. The seal assembly includes a weatherstrip and a molded component having opposing surfaces and coupled to the weatherstrip. The molded component defines an attachment hole passing through the opposing surfaces. The seal assembly also includes a fastener configured to be disposed within the attachment hole for coupling the weatherstrip and the molded component to the vehicle. The seal assembly further includes an electromagnetic adhesive applied to the molded component about the attachment hole with the electromagnetic adhesive bonding the weatherstrip to the molded component and limiting ingress of contaminants through the attachment hole. The electromagnetic adhesive includes a resin impregnated with a plurality of susceptor particles configured to be energized upon exposure to electromagnetic energy such that the plurality of susceptor particles softens the resin to bond the weatherstrip to the molded component.

Description

SEAL ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all benefits of United States Provisional Patent Application No. 63 / 599,216, filed November 15, 2023, which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The invention generally relates to a seal assembly, and to a method of manufacturing the seal assembly.2. Description of the Related Art

[0003] Conventional seal assemblies for vehicles can include a molded component and a weatherstrip coupled to the molded component. The molded component provides a rigid support structure, while the weatherstrip is at least partially flexible to provide a sealing surface. The molded component and the weatherstrip are typically coupled together through either mechanical fasteners or tape. Often, molded components of conventional seal assemblies define an attachment hole through which a fastener is disposed to attach the conventional seal assemblies to the vehicle.

[0004] However, the fastener of conventional seal assemblies may not form an adequate seal with the molded component. As such, the attachment hole defined by the molded component is susceptible to ingress of contaminants, which can result in the interior of the vehicle becoming dirty, wet, or otherwise open to the exterior environment of the vehicle. The interior of the vehicle thus becomes susceptible to rusting and / or becoming aesthetically unappealing.Moreover, the mechanical fasteners or tape which typically couple the molded component and the weatherstrip together may not assist in preventing ingress of contaminants through the attachment hole, and themselves also permit ingress of contaminants between the molded component and the weatherstrip.

[0005] As such, there remains a need for an improved seal assembly.SUMMARY OF THE INVENTION AND ADVANTAGES

[0006] The invention includes a seal assembly adapted to be coupled to a vehicle. The seal assembly includes a weatherstrip and a molded component having opposing surfaces and coupled to the weatherstrip. The molded component defines an attachment hole passing through the opposing surfaces. The seal assembly also includes a fastener configured to be disposed within the attachment hole for coupling the weatherstrip and the molded component to the vehicle. The seal assembly further includes an electromagnetic adhesive applied to the molded component about the attachment hole with the electromagnetic adhesive bonding the weatherstrip to the molded component and limiting ingress of contaminants through the attachment hole. The electromagnetic adhesive includes a resin impregnated with a plurality of susceptor particles configured to be energized upon exposure to electromagnetic energy such that the plurality of susceptor particles softens the resin to bond the weatherstrip to the molded component.

[0007] The invention also includes a method of manufacturing the seal assembly having the weatherstrip, the electromagnetic adhesive comprising the resin impregnated with the plurality of susceptor particles, and the molded component having the support section and the mounting section. The mounting section defines the attachment hole through the molded component. The method comprising the steps of:disposing a fastener in the attachment hole defined by the molded component; applying the electromagnetic adhesive to the mounting section about the attachment hole of the molded component; abutting the weatherstrip to the molded component such that at least a portion of the weatherstrip engages the electromagnetic adhesive; energizing the plurality of susceptor particles with electromagnetic energy to soften the electromagnetic adhesive resin such that the electromagnetic adhesive bonds the weatherstrip to the molded component and limits ingress of contaminants through the attachment hole in the mounting section.

[0008] As such, the weatherstrip is directly bonded to the molded component without a need for mechanical fastening or tape. Moreover, mechanical fastening of the seal assembly to the vehicle via the fastener is accomplished without undue ingress of contaminants through the attachment hole. Moreover, because ingress of contaminants is limited by the seal assembly, an interior of the vehicle remains free of rust and aesthetically appealing.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

[0010] Figure 1 is a perspective view of a molded component defining a plurality of attachment holes suitable for use in a seal assembly.

[0011] Figure 2A is a perspective view of an electromagnetic adhesive applied to the molded component, with the electromagnetic adhesive disposed about the plurality of attachment holes in a first configuration.

[0012] Figure 2B is a perspective view of another embodiment of the electromagnetic adhesive applied to the molded component, with the electromagnetic adhesive disposed about the plurality of attachment holes in a second configuration.

[0013] Figure 3 is a perspective view of a sealing lip coupled to the molded component.

[0014] Figure 4 is a perspective view of a plurality of fasteners disposed in the plurality of attachment holes of the molded component.

[0015] Figure 5 is a perspective view of the seal assembly, with the seal assembly including a weatherstrip mounted to the molded component.

[0016] Figure 6A is a cross-sectional view of the seal assembly of Figure 5 taken along line 6-6, with a presser foot shown in phantom.

[0017] Figure 6B is a cross-sectional view of the seal assembly of Figure 5 taken along line 6-6, with the presser foot shown engaging the seal assembly.

[0018] Figure 7A is a cross-sectional view of the seal assembly of Figure 5 taken along line 7-7.

[0019] Figure 7B is an exploded cross-sectional view of the seal assembly of Figure7A.

[0020] Figure 8 is a cross-sectional view of the seal assembly of Figure 5 taken along line 8-8.

[0021] Figure 9 is a cross-sectional view of an alternative seal assembly.DETAILED DESCRIPTION OF THE INVENTION

[0022] With reference to the Figures, wherein like numerals indicate like parts throughout the several views, a seal assembly 10 adapted to be coupled to a vehicle is shown in Figure 5. Referring to Figures 5-8, the seal assembly 10 includes a weatherstrip 12 and a molded component 14 with the weatherstrip 12 coupled to the molded component 14. The molded component 14 has opposing surfaces 38, 40 and the molded component 14 defines at least one attachment hole 16 passing through the opposing surfaces 38, 40. The weatherstrip 12 has an inner surface 60 bonded to the molded component 14 and an outer surface 62 facing away from the inner surface 60. The seal assembly 10 also includes a fastener 18 configured to be disposed within the attachment hole 16 for coupling the weatherstrip 12 and the molded component 14 to the vehicle. The seal assembly 10 further includes an electromagnetic adhesive 20 applied to the molded component 14 about the attachment hole 16 with the electromagnetic adhesive 20 bonding the weatherstrip 12 to the molded component 14 and limiting ingress of contaminants through the attachment hole 16. The electromagnetic adhesive 20 includes a resin impregnated with a plurality of susceptor particles configured to be energized upon exposure to electromagnetic energy such that the plurality of susceptor particles softens the resin to bond the weatherstrip 12 to the molded component 14. Figure 9 illustrates an alternative embodiment of the seal assembly 10 as discussed in greater detail below.

[0023] In the subject invention, the weatherstrip 12 is directly bonded to the molded component 14 without a need for mechanical fastening or tape. Moreover, mechanical fastening of the seal assembly 10 to the vehicle through one or more fasteners 18 is accomplished without undue ingress of contaminants through the attachment hole(s) 16. Moreover, because ingress of contaminants is limited by the seal assembly 10, an interior of the vehicle remains free of rust and aesthetically appealing.

[0024] Although not required, the fastener 18 may be a push-pin fastener 18 and may be applied to the molded component 14 before or after the electromagnetic adhesive 20 is applied. At least some of the fasteners 18 are preferably applied to the molded component 14 prior to the weatherstrip 12 being bonded to the molded component 14. The fastener 18, when disposed in the attachment hole 16, may leave voids susceptible for ingress of contaminants. The electromagnetic adhesive 20 both bonds the weatherstrip 12 to the molded component 14 and limits, or prevents, contaminants such as dirt and water from entering the attachment hole 16. Thus, the seal assembly 10 is able to include fasteners 18 to join the seal assembly 10 with the vehicle while advantageously still resulting in a water-tight seal about the fasteners 18 and the attachment holes 16 which are typically otherwise susceptible to contamination. In addition to using electromagnetic adhesives, there are other sealing techniques, such as tape or the weatherstrip itself, that could be implemented to provide additional sealing. It is to be appreciated, that not all of the fasteners need to be applied to the molded component 14 prior to bonding the weatherstrip 12.

[0025] In non-limiting examples, the seal assembly 10 may be used in combination with a door of the vehicle, a window of the vehicle, a moonroof of the vehicle, or a rear-hatch of the vehicle, among other possibilities. Specifically, locations where this type of seal assembly 10 could be implemented are front closures, like a hood margin seal, or, in the case of an electric vehicle, it could be applied to the frunk tub, which is often a molded component itself. In rear closures, the seal assembly 10 might be used for a liftgate / decklid margin seal or a liftgate / decklid gutter cover, which is a type of trim piece more than a weatherstrip. For side closures, the seal assembly 10 might be applied to a door margin seal, i.e., door- to -fender seal, door-to-door seal, rear margin seal, or pillar applique seal. In the most preferred embodiments, the seal assembly 10would be used in applications requiring a margin seal, which are sometimes also known as cutline seals, that bridge a gap between one vehicle closure panel to another panel.

[0026] The fastener or fasteners 18 would extend through the attachment hole 16 defined by the molded component 14 to enable attachment of the seal assembly 10 to the desired vehicle location. In the non-limiting exemplary embodiment, the seal assembly 10 can be attached to a C-pillar of the vehicle by the fastener(s) 18. Although not necessary, the attachment hole may lead directly into a void between adjacent body panels of the vehicle. In these embodiments, ensuring a water-tight seal about the attachment hole 16 and the fastener 18 is particularly advantageous.

[0027] It is to be appreciated that the molded component 14 may be directly mounted to the weatherstrip 16 through the electromagnetic adhesive 20 without mechanical fastening between the molded component 14 and the weatherstrip 16. Direct mounting of the molded component 14 and the weatherstrip 16 can thus be accomplished inexpensively and with reduced manufacturing time. Moreover, the electromagnetic adhesive 20 results in a strong bond between the molded component 14 and the weatherstrip 16, and thus the direct mounting of the molded component 14 to the weatherstrip 16 is secure.

[0028] In the most preferred embodiment, at least a portion of the electromagnetic adhesive 20 is applied to the molded component 14 about a majority of the attachment hole(s) 16 to limit ingress of contaminants through the attachment hole 16. In a non-limiting example shown in Figures 2A, 3, and 4, at least a portion of the electromagnetic adhesive 20 completely surrounds each attachment hole 16, such as in a circle, square, or any other shape. However, the electromagnetic adhesive 20 need not completely surround the attachment hole(s) 16. Instead, in other non-limiting examples such as shown in Figure 2B, the electromagnetic adhesive 20 mayform an arc (e.g., a crescent, a U-shape) about the attachment hole(s) 16. The arc may terminate in an opening, and the opening may be configured to be vertically aligned upon attachment of the seal assembly 10 to the vehicle. By vertically aligning the opening defined by the arc with the ground, it is still possible to limit or prevent ingress of contaminants into the attachment hole 16. More specifically, the force of gravity tends to pull contaminants toward the ground, and thus the contaminants are still not able to enter the attachment hole 16 while the electromagnetic adhesive 20 forms an arc about the attachment hole 16 if the opening of the arc is vertically aligned relative to the ground.

[0029] In the embodiment shown, the attachment hole 16 is further defined as a first attachment hole 16, and the molded component 14 defines a plurality of attachment holes 16. The fastener 18 of the seal assembly 10 is further defined as a first fastener 18, and the seal assembly 10 further includes a plurality of fasteners 18. Although not required, each of the plurality of fasteners 18 may be disposable in one of the plurality of attachment holes 16. At least a portion of the electromagnetic adhesive 20 may be applied to the molded component 14 such that the electromagnetic adhesive 20 limits ingress of contaminants through the plurality of attachment holes 16. Moreover, at least a portion of the electromagnetic adhesive 20 may be disposed about a majority of each of the plurality of attachment holes 16 to limit ingress of contaminants through each attachment hole 16. However, there may also be one or more additional attachment holes 16 and one or more associated fasteners 18 disposed in the one or more attachment holes 16 without associated electromagnetic adhesive 20 applied about the one or more attachment holes 16. As mentioned above, there are other techniques available to seal these other holes 16. Also, there may be applications where seal contaminants is important in one area of the seal assembly 10 and / orvehicle, but either not critical or accounted for through other means in another area of the seal assembly 10 and / or the vehicle.

[0030] Further still, as shown in Figure 2B, at least a portion of the electromagnetic adhesive 20 may form an arc about at least two (e.g., two or more) of the plurality of attachment holes 16. As discussed herein, the arc may terminate in an opening. The opening defined by the arc may be configured to be vertically aligned upon attachment of the seal assembly 10 to the vehicle. In so doing, it is still possible to limit or prevent ingress of contaminants into the two or more attachment holes 16. More specifically, the force of gravity tends to pull contaminants toward the ground, and thus the contaminants are still not able to enter the two or more attachment holes 16 while electromagnetic adhesive 20 forms an arc about the attachment hole 16 if the opening of the arc is oriented relative to the ground. In the embodiment as shown in Figure 2B, the electromagnetic adhesive 20 is still considered to be applied about a majority of the attachment holes 16.

[0031] Although Figure 2B illustrates the electromagnetic adhesive 20 applied as a single arc, it is also contemplated that multiple arcs of electromagnetic adhesive 20 may be applied to the molded component 14. The multiple arcs may each correspond to one of the plurality of attachment holes 16. Alternatively, the multiple arcs may be applied such that two or more arcs together are applied about one or more attachment holes 16. Multiple arcs are particularly advantageous at the attachment hole 16 most distal to the ground due to its tendency to receive the largest amount of exposure to contamination (e.g., dirt and water). The multiple arcs thus serve as a redundant measure to ensure a water-tight seal.

[0032] Additionally, although not required, there may be at least a portion of the electromagnetic adhesive 20 applied as a continuous line 22 between at least two of the pluralityof attachment holes 16. The continuous line 22 between adjacent attachment holes 16 thus provides a continuous, high-strength, uninterrupted bond between the weatherstrip 12 and the molded component 14. The continuous, high-strength, uninterrupted bond between the weatherstrip 12 and the molded component 14 limits, or prevents, contaminants such as dirt and water from traveling therethrough, thus ensuring a water-tight seal therebetween.

[0033] The molded component 14 may be of any suitable configuration as dictated by the application mentioned above. The molded component 14 can be of any suitable material to which a sealing component, such as a weatherstrip and / or sealing lip, can be attached.

[0034] As perhaps best shown in sectional views of Figures 6A-7B and 9, the molded component 14 may include a first locating component 24 and the weatherstrip 16 may include a second locating component 26 engageable with the first locating component 24 of the molded component 14 to orient the weatherstrip 16 relative to the molded component 14. The first locating component 24 may extend away from the molded component 14, such as shown, or may be indented into the molded component 14. The second locating component 26 may be either indented into the weatherstrip 12 (as shown) or may extend away from the weatherstrip 12. The first locating component 24 and the second locating component 26 are useful for an operator to locate the correct placement, alignment, and / or orientation of the weatherstrip 12 to the molded component 14 before the electromagnetic adhesive 20 bonds the weatherstrip 12 to the molded component 14. Further, the locating components 24, 26 can be positioned in the relative center of the weatherstrip 16, such as shown in Figures 6A-7B, or can be positioned near an edge of the weatherstrip 16, such as shown in Figure 9.

[0035] The first locating component 24 may be further defined as a protrusion 24, and the second locating component 26 may be further defined as a groove 26. The protrusion 24extends from the molded component 14, and the groove 26 is indented into the weatherstrip 16.The protrusion 24 is disposable in the groove 26 to engage the first locating component 24 and the second locating component 26. The protrusion 24 of the molded component 14 may be further defined as a locating ridge 24. Although not required, the electromagnetic adhesive 20 may be applied to the molded component 14 such that the electromagnetic adhesive 20 extends approximately parallel to the first locating component 24. In other words, the electromagnetic adhesive 20 may be adjacent to the first locating component 24.

[0036] As shown in FIGS. 6A-8, the molded component 14 may form an indentation 42 or recessed area for receiving the electromagnetic adhesive 20. As shown in Figures 6A-6B, the indentation 42 or recess can be defined relative to another area of the molded component 14. As one non-limiting example, the indentation or recess 42 may be relative to a platform 64, which is a raised portion of the molded component 14. The electromagnetic adhesive 20 has a defined thickness, and the platform 64 preferably has a defined height similar to the defined thickness to ensure consistent orientation of the weatherstrip 12 onto the molded component 14, Turning to Figures 7A-8, the indentation 42 may be about the attachment hole 16. The fastener 18 may include a fastener head 44 and a fastener body 46 extending away from the fastener head 44. The fastener 18 may be configured to be seated within the indentation 42 such that the fastener head 44 contacts the indentation 42 and the fastener body 46 extends through the attachment hole 16. Moreover, at least a portion of the electromagnetic adhesive 20 may be disposed about the indentation 42 formed about the attachment hole 16. Although not required, the indentation 42 may be formed as a first step 48 and a second step 50 indented relative to the first step 48. At least a portion of the electromagnetic adhesive 20 may be disposed in the first step 48 of the indentation 42, such as shown in Figures 7A-7B. The fastener head 44 may be disposed inthe second step 50 of the indentation 42. As shown in Figure 8, the electromagnetic adhesive 20 may be disposed both within the step and outside of the step. It is to be appreciated that the indentation or recess 42 may be provided is discrete areas of the molded component 14 such that the indentation or recess 42 not utilized, such as shown in Figure 9, may be eliminated altogether. For illustrative purposes, the platform 64 is not shown in Figures 1-4.

[0037] The weatherstrip 12 may comprise a thermosetting material, a thermoplastic material, a rubber material such as, but not limited to, ethylene propylene diene monomer (“EPDM”) rubber, and / or may comprise a thermoplastic elastomer (“TPE”) such as, but not limited to, thermoplastic vulcanizates (“TPV”) and / or thermoplastic olefins (“TPO”). The molded component 14 may comprise either a thermoplastic material, such as, but not limited to, polypropylene (“PP”), or a thermosetting material. As discussed above, the electromagnetic adhesive 20 includes the resin impregnated with susceptor particles, which provides excellent bonding between the material(s) of the weatherstrip 12 and the material(s) of the molded component 14. It is to be appreciated that the molded component 14 may be molded separately from the weatherstrip 12, and that the weatherstrip 12 may be extruded separately from the molded component 14.

[0038] The seal assembly 10 may further include a sealing lip 28 coupled to the molded component 14 at a distal edge of the molded component 14. It is to be appreciated that the sealing lip 28 is often known as a margin seal, and is mounted to a distal edge of the molded component 14 as known in the art. The sealing lip 28 may be co-molded onto the molded component 14 such as through injection molding. The molded component 14 is shown without the sealing lip in Figures 1-2B. The sealing lip 28 may include surfaces which are flocked. The sealing lip 28 may be comprised of a thermoplastic elastomer (“TPE”) such as, but not limited to,thermoplastic vulcanizates (“TPV”) and / or thermoplastic olefins (“TPO”). In the illustrated example, the sealing lip 28 is contactable with a closure of a vehicle (such as a door) to seal the vehicle door relative to a body, and / or frame, of the vehicle. The sealing lip 28 need not extend completely along the molded component 14, but instead may leave a notch 30 to provide room to mate with other vehicle components such as, but not limited to, a wheel housing seal.

[0039] Additionally, although not required, the weatherstrip 12 may include at least one chosen from a sealing lip and a sealing bulb, depending upon the particular application in the vehicle. As shown in Figures 5-9, the weatherstrip 12 includes a sealing bulb. The weatherstrip 12 may have a relatively small surface area and may also include surfaces which are flocked. Flocked surfaces are particularly sensitive to both pressure and heat during the manufacture of the weatherstrip 12, and thus pose a challenge to manufacture. However, flocked surfaces may be extruded. As such, the majority of the weatherstrip 12 may be extruded.

[0040] Although not required, the weatherstrip 12 may also include a molded end component 32 at an end of the weatherstrip 12. The molded end component 32 may be applied after extrusion of the weatherstrip 12. The molded end component 32 is molded, such as, but not limited to, injection molded. The attachment hole 16 may be further defined as an end attachment hole 58 defined at an end of the molded component 14. The fastener 18 may be further defined as an end fastener 56 configured to be disposed in the end attachment hole 58. The molded end component 32 may be molded to encapsulate a portion of the end fastener 56. More specifically, as part of the molded operation for the molded end component 32, the end fastener 56 can be comolded into the molded end component 32, which is illustrated in Figure 8. This provides for improved installation of the weatherstrip 12 to the molded component 14 in order to further locatethe correct placement, alignment, and / or orientation of the weatherstrip 12 to the molded component 14 prior to bonding the weatherstrip 12 to the molded component 14.

[0041] Referring also to Figures 1-5, the general operational steps are shown. The molded component 14 may be molded, such as, but not limited to, injection molded as shown in Figure 1. The weatherstrip 12 may be partially extruded, thus permitting flocked surfaces on the weatherstrip 12, if desired, in a separate step. The molded end components 32 are applied to the extruded weatherstrip 12 in a separate molding operation.

[0042] To reduce the complexity of attaching the weatherstrip 12 to the molded component 14, the electromagnetic adhesive 20 may be applied onto the molded component 14 while the molded component 14 remains in the mold, such as shown in Figures 2A and alternatively in 2B. The electromagnetic adhesive 20 may be robotically applied or applied by hand to the molded component 14.

[0043] As mentioned above, a sealing lip 28 is applied to the molded component 14, and is more specifically applied to a distal edge of the molded component 14 as shown in Figure 3. The sealing lip 28 is preferably co-molded onto the molded component 14, such as through injection molding. It is to be appreciated that the application of the sealing lip 28 and the electromagnetic adhesive 20 are done in two steps, and may be in either order without deviating from the scope of the invention. Meaning, the sealing lip 28 could be applied first, and then the electromagnetic adhesive 20 is applied.

[0044] As shown in Figure 4, certain fasteners of the plurality of fasteners 18 are disposed in selected attachment holes 16. In the embodiment shown, the two outer-most attachment holes 16 do not include fasteners at this time. It is to be appreciated, that any number of suitable fasteners 18 can be applied to the molded component 14. Further, the application ofthe fasteners 18 could be done before the application of the electromagnetic adhesive 20 and / or before the application of the sealing lip 28.

[0045] The weatherstrip 12 is then applied to the molded component 14 over the electromagnetic adhesive 20 and the inserted fasteners 18 as shown in Figure 5. The outer-most attachment holes 16 receive the co-molded fasteners 18 from the weatherstrip 12. This now forms the defined seal assembly.

[0046] In a non-limiting example, the weatherstrip 12 is bonded to the molded component 14 by the electromagnetic adhesive 20 through use of an electromagnetic welding machine including a radiofrequency (RF) coil 34. It is to be appreciated that the RF coil is shown schematically in the figures. The RF coil 34 may be cooled, for example, by a coolant such as water. The RF coil 34 melts the electromagnetic adhesive 20 to bond the weatherstrip 12 to the molded component 14. A presser foot 36 may also be provided to force the weatherstrip 12 and molded component 14 together. The presser foot 36 may force the weatherstrip 12 toward the molded component 14, or may force the molded component 14 toward the weatherstrip 12. As shown in Figures 6A-8, the presser foot 36 applies a force along a majority, if not all, of the length of the weatherstrip 12. It is to be appreciated that the presser foot 36 is shown schematically in the figures.

[0047] In the embodiments where the electromagnetic adhesive 20 includes resin impregnated with susceptor particles, the RF coil 34 melts the resin impregnated with susceptor particles to bond the weatherstrip 12 to the molded component 14. More specifically, the RF coil 34 energizes the susceptor particles impregnated in the resin with radiofrequency (“RF”) energy in a process which may be described as electromagnetic welding. The energized susceptor particles impregnated in the resin melt the resin, which then bonds the weatherstrip 12 to the moldedcomponent 14 to ensure excellent sealing characteristics (e.g. a water-tight seal) between the weatherstrip 12 and the molded component 14.

[0048] As shown in Figure 6A and 6B, which are cross-sectional views taken along line 6-6 of Figure 5, the electromagnetic adhesive 20 need not be applied about each and every attachment hole 16. Instead, as described herein, there may be additional attachment holes 16 that are not sealed by the electromagnetic adhesive 20. However, Figure 6A and 6B also show that the electromagnetic adhesive 20 may be applied in the continuous line 22 to the molded component 14. The electromagnetic adhesive 20 may also be applied adjacent to the locating ridge 24 on the molded component 14, optionally as the continuous line 22. Due to the relative strength of the bond formed by the electromagnetic adhesive 20, such as the bond formed when using an electromagnetic adhesive 20, it is largely unnecessary to apply the electromagnetic adhesive 20 to both sides of the locating ridge 24, although applying the electromagnetic adhesive 20 to both sides of the locating ridge 24 is contemplated herein. Further, the width or thickness of the electromagnetic adhesive 20 could vary, such as shown in the different sectional views in Figures 6A-9.

[0049] As shown in Figures 7A and 7B, which are cross-sectional views taken along line 7-7 of Figure 5, the electromagnetic adhesive 20 is disposed about the attachment hole 16 and the fastener 18. In other words, the electromagnetic adhesive 20 may be applied on both sides or all sides of the attachment hole 16. As shown in Figure 8, which is a cross-sectional view taken along line 8-8 of Figure 5, the electromagnetic adhesive 20 is disposed about another of the plurality of attachment holes 16 and the plurality of fasteners 18, in this case a co-molded fastener 18. In other words, the electromagnetic adhesive 20 may be applied to both sides or all sides of another attachment hole 16. While Figures 6A-7B disclose the sealing lip 28, Figure 8 does not.As can be seen in Figure 5, line 8-8 is taken at the notch 30 provided so that there is room to mate the seal assembly 10 to other vehicle components.

[0050] As shown in Figure 4, and as discussed above, all of the fasteners 18 need not be disposed in the attachment holes 16 prior to the weatherstrip 12 being installed and bonded to the molded component 14. Instead, as also discussed above, the fasteners 18 may be molded with the weatherstrip 12 such that the fasteners 18 are immobilized relative to the weatherstrip 12. As shown in Figure 8, the fasteners 18 may be partially encapsulated by the molded end components 32. In the embodiments where the fasteners 18 are partially encapsulated by the molded end components 32, it is to be appreciated that the fasteners 18 are disposed in the attachment holes 16 at approximately the same time as the groove or tab 26 of the weatherstrip 12 is engaged with the locating ridge 24 of the molded component 14.

[0051] Moreover, the molded component 14 has a support section 52 and a mounting section 54. The mounting section 54 defines the attachment hole 16 through the molded component 14. The molded component 14, therefore, also has electromagnetic adhesive 20 applied to the mounting section 54. The support section 52 provides support for the seal assembly 10 between adjacent mounting sections(s) 54.

[0052] A method of manufacturing the seal assembly 10 is also provided. With reference back to all of the Figures, the method includes the step of disposing the fastener 18 in the attachment hole 16 defined by the molded component 14. The method also includes the step of applying the electromagnetic adhesive 20 to the mounting section 54 about the attachment hole 16 of the molded component 14. The method further includes the step of abutting the weatherstrip 12 to the molded component 14 such that at least a portion of the weatherstrip 12 engages the electromagnetic adhesive 20. The method further includes the step of energizing the plurality ofsusceptor particles with electromagnetic energy to soften the electromagnetic adhesive resin such that the electromagnetic adhesive bonds the weatherstrip 12 to the molded component 14 and limits ingress of contaminants through the attachment hole 16 in the mounting section 54.

[0053] Although not required, the step of applying the electromagnetic adhesive 20 to the molded component 14 may be further defined as applying at least a portion of the electromagnetic adhesive 20 about a majority of the attachment hole 16 to limit ingress of contaminants through the attachment hole 16.

[0054] The method may also include the step of molding the molded component 14 defining the attachment hole 16 in a first molding step. The step of molding the molded component 14 may be accomplished in a one-shot process. The intermediate product of the seal assembly 10 created by the step of molding the molded component 14 is shown in Figure 1. In a non-limiting example, the step of applying the electromagnetic adhesive 20 to the molded component 14 is accomplished in a second molding step directly onto the molded component 14. The step of applying the electromagnetic adhesive 20 to the molded component 14 may be accomplished in second-shot process directly onto the molded component 14. The intermediate product of the seal assembly 10 created by the step of applying the electromagnetic adhesive 20 to the molded component 14 is shown in Figures 2A and alternative 2B.

[0055] The method further includes the step of applying the sealing lip 28 to the molded component 14. The step of applying the sealing lip 28 to the molded component 14 may be accomplished in a third molding step directly onto the molded component 14. The step of applying the sealing lip 28 to the molded component 14 may be accomplished as a third-shot process directly onto the molded component 14. The intermediate product of the seal assembly 10 created by the step of applying the seal assembly 10 to the molded component 14 is shown inFigure 3. As also mentioned above, the steps of applying the electromagnetic adhesive 20 and sealing lip 28 could be reversed, which still results in the same intermediate product shown in Figure 3.

[0056] As described herein, the method further includes the step of disposing at least some of the fastener 18 in the attachment hole 16 defined by the molded component 14. It is to be appreciated that this step may be further defined as disposing a plurality of fasteners 18 in the plurality of attachment holes 16 defined by the molded component 14. The intermediate product of the seal assembly 10 created by the step of disposing the plurality of fasteners 18 in the plurality of attachment holes 16 defined by the molded component 14 is shown in Figure 4. This step could also be in a different order relative to the steps for the sealing lip 28 and the electromagnetic adhesive 20, but would still result in the same intermediate product shown in Figure 4.

[0057] The method may further include the step of providing the weatherstrip 12, which was pre-extruded and / or pre-molded in a separate operation, and applying this weatherstrip 12 to the intermediate product shown in Figure 4. The method may further include the step of engaging the first locating component 24 of the molded component 14 with the second locating component 26 of the weatherstrip 26 to orient the molded component 14 relative to the weatherstrip 12. More specifically, the method may further include the step of engaging the corresponding groove or tab 26 of the weatherstrip 12 with the locating ridge 24 of the molded component 14. The step of engaging groove or tab 26 of the weatherstrip 12 with the locating ridge 24 of the molded component 14 places, aligns, and / or orients the weatherstrip 12 relative to the molded component 14. Simultaneously, the co-molded fasteners 18 are inserted into the remaining attachment holes(s) 16 to further place, align, and / or orientate the weatherstrip 12 relative to themolded component 14. The method may further include molding the end component 32 onto an end of the weatherstrip 12 such that the molded end component 32 encapsulates a portion of the end fastener 56.

[0058] As described herein, in the most preferred embodiment, the method further includes the step of energizing an electromagnetic adhesive 20 to bond the weatherstrip 12 to the molded component 14. The step of energizing the electromagnetic adhesive 20 may include the step of aligning the molded component 14, the electromagnetic adhesive 20, the fastener 18, and the weatherstrip 12 with an electromagnetic welding machine having a radiofrequency (“RF”) coil 34 and the step of activating the radiofrequency coil 34 to energize the plurality of susceptor particles and soften the electromagnetic resin 20. The step of energizing the electromagnetic adhesive 20 may further include the step of applying a presser foot 36 to force the molded component 14 and the weatherstrip 12 together. The step of applying the presser foot 36 to force the molded component 14 and the weatherstrip 12 may be accomplished concurrently with the step of activating the radiofrequency coil 34 to energize the plurality of susceptor particles and soften the electromagnetic adhesive 20. Moreover, the mounting section 54 may be further defined as a plurality of mounting sections 54 each defining an attachment hole 16, and the method may further include the step of applying the electromagnetic adhesive 20 to the support section 52 as a continuous line between adjacent mounting sections 54. The seal assembly 10 manufactured by the method is shown in Figure 5.

[0059] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present inventionare possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

[0060] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

Claims

CLAIMSWhat is claimed is:

1. A seal assembly adapted to be coupled to a vehicle, said seal assembly comprising: a weatherstrip; a molded component having opposing surfaces and coupled to said weatherstrip, with said molded component defining an attachment hole passing through said opposing surfaces; a fastener configured to be disposed within said attachment hole for coupling said weatherstrip and molded component to the vehicle; and an electromagnetic adhesive applied to said molded component about said attachment hole with said electromagnetic adhesive bonding said weatherstrip to said molded component and limiting ingress of contaminants through said attachment hole; wherein said electromagnetic adhesive comprises a resin impregnated with a plurality of susceptor particles configured to be energized upon exposure to electromagnetic energy such that said plurality of susceptor particles softens said resin to bond said weatherstrip to said molded component.

2. The seal assembly as set forth in claim 1, wherein at least a portion of said electromagnetic adhesive is disposed about a majority of said attachment hole to limit ingress of contaminants through said attachment hole.

3. The seal assembly as set forth in claim 1, wherein at least a portion of said electromagnetic adhesive completely surrounds said attachment hole.

4. The seal assembly as set forth in claim 1, wherein at least a portion of said electromagnetic adhesive is formed as an arc about said attachment hole.

5. The seal assembly as set forth in claim 4, wherein said arc terminates in an opening, and wherein said opening is configured to be vertically aligned upon attachment of said seal assembly to the vehicle.

6. The seal assembly as set forth in claim 1, wherein said molded component comprises a first locating component and said weatherstrip comprises a second locating component engageable with said first locating component of said molded component to orient said weatherstrip relative to said molded component.

7. The seal assembly as set forth in claim 6, wherein said first locating component is further defined as a protrusion, wherein said second locating component is further defined as a groove, and wherein said protrusion is disposable in said groove to engage said first locating component and said second locating component.

8. The seal assembly as set forth in claim 6, wherein said electromagnetic adhesive is applied to said molded component such that said electromagnetic adhesive extends approximately parallel to said first locating component.

9. The seal assembly as set forth in claim 1, wherein said attachment hole defined by said molded component is further defined as a plurality of attachment holes, and wherein at least a portion of the electromagnetic adhesive is applied to said molded component such that said electromagnetic adhesive limits ingress of contaminants through said plurality of attachment holes.

10. The seal assembly as set forth in claim 9, wherein at least a portion of said electromagnetic adhesive is disposed about a majority of each attachment hole to limit ingress of contaminants through each attachment hole.

11. The seal assembly as set forth in claim 9, wherein at least a portion of said electromagnetic adhesive is formed as an arc about at least two of said plurality of attachment holes.

12. The seal assembly as set forth in claim 11, wherein said arc terminates in an opening, and wherein said opening is configured to be vertically aligned upon attachment of said seal assembly to the vehicle.

13. The seal assembly as set forth in claim 9, wherein at least a portion of said electromagnetic adhesive is applied as a continuous line between at least two of said plurality of attachment holes.

14. The seal assembly as set forth in claim 1, wherein said weatherstrip comprises a molded end component at an end of the weatherstrip, wherein said attachment hole is further defined as an end attachment hole defined at an end of said molded component, wherein said fastener is further defined as an end fastener configured to be disposed in said end attachment hole, and wherein said molded end component has been molded to encapsulate a portion of said end fastener.

15. The seal assembly of claim 1, wherein said molded component is directly mounted to said weatherstrip through said electromagnetic adhesive without mechanical fastening between said molded component and said weatherstrip.

16. The seal assembly as set forth in claim 1 further comprising a sealing lip coupled to said molded component at a distal edge of said molded component.

17. The seal assembly as set forth in claim 1, wherein said weatherstrip comprises at least one chosen from a sealing lip and a sealing bulb.

18. The seal assembly as set forth in claim 1, wherein said molded component forms an indentation about said attachment hole, wherein said fastener comprises a fastener head and a fastener body extending away from said fastener head, and wherein said fastener is configured to be seated within said indentation such that said fastener head contacts said indentation and said fastener body extends through said attachment hole.

19. The seal assembly as set forth in claim 18, wherein at least a portion of said electromagnetic adhesive is disposed in said indentation.

20. The seal assembly as set forth in claim 18, wherein said indentation is formed as a first step and a second step indented relative to said first step, and wherein at least a portion of said electromagnetic adhesive is disposed in said first step of said indentation.

21. A method of manufacturing a seal assembly adapted to be coupled to a vehicle, the seal assembly having a weatherstrip, an electromagnetic adhesive comprising a resin impregnated with a plurality of susceptor particles, and a molded component having a support section and a mounting section, wherein the mounting section defines an attachment hole through the molded component, the method comprising the steps of: disposing a fastener in the attachment hole defined by the molded component; applying the electromagnetic adhesive to the mounting section about the attachment hole of the molded component; abutting the weatherstrip to the molded component such that at least a portion of the weatherstrip engages the electromagnetic adhesive; and energizing the plurality of susceptor particles with electromagnetic energy to soften the electromagnetic adhesive resin such that the electromagnetic adhesive bonds the weatherstrip tothe molded component and limits ingress of contaminants through the attachment hole in the mounting section.

22. The method as set forth in claim 21, wherein the step of applying the electromagnetic adhesive to the molded component is further defined as applying at least a portion of the electromagnetic adhesive about a majority of the attachment hole to limit ingress of contaminants through the attachment hole.

23. The method as set forth in claim 21 further comprising the step of: molding the molded component defining the attachment hole in a first molding step; and wherein the step of applying the electromagnetic adhesive to the molded component is accomplished in a second molding step directly onto the molded component.

24. The method as set forth in claim 23, further comprising the step of: applying a sealing lip to the molded component as a third molding step directly onto the molded component.

25. The method as set forth in claim 21, wherein the molded component comprises a first locating component and the weatherstrip comprises a second locating component, the method further comprising the step of: engaging the first locating component of the molded component with the second locating component of the weatherstrip to orient the molded component relative to the weatherstrip.

26. The method as set forth in claim 21, wherein the attachment hole is further defined as an end attachment hole defined at an end of the molded component, wherein the fastener is further defined as an end fastener configured to be disposed in the end attachment hole, and wherein the method further comprises the step of:molding an end component onto an end of the weatherstrip such that the molded end component encapsulates a portion of the end fastener.

27. The method as set forth in claim 21, wherein the step of energizing the electromagnetic adhesive comprises the steps of: aligning the molded component, the electromagnetic adhesive, the fastener, and the weatherstrip with an electromagnetic welding machine having a radiofrequency coil; and activating the radiofrequency coil to energize the plurality of susceptor particles and soften the electromagnetic adhesive.

28. The method as set forth in claim 27, wherein the step of energizing the electromagnetic adhesive comprises the step of: applying a presser foot to force the molded component and the weatherstrip together, wherein the step of applying the presser foot to force the presser foot and the weatherstrip together is accomplished concurrently with the step of activating the radiofrequency coil to energize the plurality of susceptor particles and soften the electromagnetic adhesive.

29. The method as set forth in claim 21 , wherein the mounting section is further defined as a plurality of mounting sections each defining an attachment hole, and further comprising the step of applying the electromagnetic adhesive to the support section as a continuous line between adjacent mounting sections.

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