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

Abstract

A method of manufacturing a vehicle component is disclosed and includes providing a body having an extruded profile formed at least in part from a material and a notch formed through a portion of the body. The method includes placing the body with the extruded profile having a notch formed therein into a mold cavity. While in the mold cavity, the process includes both (i) bending the body at a temperature less than a melting temperature of the material from a first, linear conformation to a second, bent configuration and (ii) introducing a fill material to form (e.g., mold) a fill member into the notch of the bent body from one of the same or a different material that will join with the body material.

Description

INTEGRATED HOT BENDING AND INJECTION MOLDING WITHOUT REINFORCINGCARRIER OF EXTRUDED PROFILE COMPONENTCross-Reference to Related Application

[0001] The present application claims priority from and benefit of the filing date of U.S. provisional application Ser. No. 63 / 609,532 filed December 13, 2023, and the entire disclosure of said provisional application is hereby expressly incorporated by reference into the present application.Background

[0002] The present disclosure relates to a manufactured vehicle component, and more particularly, an extruded profile component such as a window seal assembly for an associated vehicle. More specifically, the present disclosure relates to an improved process for manufacturing the vehicle component.

[0003] Currently a process exists for manufacturing a vehicle component V as generally illustrated in Figure 1. Specifically, manufacture of the vehicle component begins with an extruded profile body B. Typically, a notch or recess N extends partially through a cross-section of the body B. Opposite ends E1 , E2 are linearly or longitudinally spaced from one another, and the notch N is provided between the opposite ends. Particularly, a portion of the body B between the ends E1 and E2 undergoes a bending operation, and the notch N is located at a generally mid-span or mid-length location of the bend in the body. For example, it is common to bend the linear body B as shown in the left-hand portion of Figure 1 into the bent or curved configuration B’ shown in the leftcentral portion of Figure 1. Conventional bending operations can be used to achieve the bent configuration B’. In one instance, the body B is exposed to a heating operation elevated temperature to soften the body B that allow the opposite ends E1, E2 to be brought toward each other, and where the notch N is located at a vertex of included obtuse angle (i.e., an included angle between 90° and 180°). Once bent to the desired angle, the body B’ is held at the desired angle until the material of the body has cooled, cured, or set to retain the desired bend angle.

[0004] Thereafter, the bent body B’ is introduced into a mold (not shown) and the bent body subject to injection molding or overmolding step where a fill material F is introduced or injected into a cavity of the mold. A desired amount of fill material F is introduced into the mold and directed into the notch N so as to form a fill member FM that fills the notch N. The fill member FM also may include linear portions extending in opposite longitudinal directions of the notch at least partially into the bent body B’. The fill material F is at least partially cured, i.e., to a degree that the bent body B’ with fill member FM maintains bent configuration / structural integrity, of the desired bent shape to mate with the contour, for example, of a sloped or bent region of a header portion of a vehicle door or vehicle door opening.

[0005] Although commercially used, improvements relating to efficiency, manufacturing processing speed cost, etc., of this prior art process are always sought. Thus, a solution that provides a functionally compatible component and that addresses one or more of these deficiencies, as well as still other advantageous features and benefits, are desirable.Summary

[0006] The present disclosure provides for an integrated hot bending and molding of an extruded profile without a reinforcement carrier of a body.

[0007] A method of manufacturing a vehicle component includes providing a body having an extruded profile formed at least in part from a material and a notch formed through a portion of the body. The method includes placing the body with the extruded profile having a notch formed therein into a mold cavity. While in the mold cavity, the process includes both (i) bending the body at a temperature less than a melting temperature of the material from a first, linear conformation to a second, bent configuration and (ii) introducing a fill material to form (e.g., mold) a fill member into the notch of the bent body from one of the same or a different material that will join with the body material.

[0008] The bending and molding steps are done at least partially simultaneously.

[0009] The providing step includes supplying the body without a reinforcement carrier.

[0010] The providing step includes initially extruding the body into a desired profile.

[0011] The bending step includes orienting the body so that the notch is located within an angle that is either acute or obtuse between a first end and a second end of the bent body.

[0012] The body orienting step locates the notch in an obtuse angle between the first and second ends of the bent body.

[0013] The body bending step includes moving at least portions of a first sidewall and a second sidewall of the notch closer to one another.

[0014] The method further includes at least partially curing the fill member to maintain the body in the second, bent configuration while the body is located in the mold cavity.

[0015] The method further includes removing the bent body with the at least partially cured fill member from the mold cavity after the partial curing step.

[0016] The method further includes using the same material for the fill member as the body material.

[0017] The method further includes using the same material for the fill member as the body material, and the same material of the fill member and the body having different durometers.

[0018] The method further includes forming a fill member with a fill member material that is different than the body material, the body material and the fill member material defining an integral structure when cured together.

[0019] The method of manufacturing a vehicle component includes manufacturing a header portion of a window seal assembly for an associated vehicle.

[0020] A primary benefit of the present disclosure is the improved process time to manufacture / produce the vehicle component.

[0021] Another advantage of the disclosure resides in the decreased difficulty with introducing the body into a mold cavity.

[0022] Yet another benefit is associated with the ability to obtain a sharper bend / radius of curvature in the finally manufactured component.

[0023] Still another advantage resides in the reduced cost associated with decreasing the number of separate operations in the manufacturing process.

[0024] Still other benefits and advantages of the present disclosure will become more apparent from reading and understanding the following detailed description.Brief Description of the Drawings

[0025] Figure 1 is a schematic representation of a prior art method of forming a bent vehicle component.

[0026] Figure 2 is a view of a vehicle component such as a door seal assembly that includes a bent region along a header portion of the component.

[0027] Figure 3 is an enlarged view of the vehicle component of Figure 2 and particularly illustrating a fill member formed in a notch of a body having an extruded profile.

[0028] Figure 4 is a schematic representation of the present method of forming a bent vehicle component.Detailed Description

[0029] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of one or more versions or embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. Various exemplary embodiments of the present 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 substitutes included in the ideas and technological scope of the appended claims. In describing the drawings, where possible similar reference numerals are used for similar elements.

[0030] The terms "include" or "may include" used in the present disclosure indicate the presence of disclosed corresponding functions, operations, elements, and the like, and do not limit additional one or more functions, operations, elements, and the like. In addition, it should be understood that the terms "include", “including”, “have” or "having" used in the present disclosure are to indicate the presence of components, features, numbers, steps, operations, elements, parts, or a combination thereof described in thespecification, and do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, parts, or a combination thereof.

[0031] The terms "or" or "at least one of A or / and B" used in the present disclosure include any and all combinations of words enumerated with them. For example, "A or B" or "at least one of A or / and B" mean including A, including B, or including both A and B.

[0032] Although the terms such as "first" and "second" used in the present disclosure may modify various elements of the different exemplary embodiments, these terms do not limit the corresponding elements. For example, these terms do not limit an order and / or importance of the corresponding elements, nor do these terms preclude additional elements (e.g., third, fourth, etc.) The terms may be used to distinguish one element from another element. For example, a first mechanical device and a second mechanical device all indicate mechanical devices and may indicate different types of mechanical devices or the same type of mechanical device. For example, a first element may be named a second element without departing from the scope of the various exemplary versions or embodiments of the present disclosure, and similarly, a second element may be named a first element.

[0033] It will be understood that, when an element is mentioned as being "connected" or "coupled" to another element, the element may be directly connected or coupled to another element, and there may be an intervening element between the element and another element. To the contrary, it will be understood that, when an element is mentioned as being "directly connected" or "directly coupled" to another element, there is no intervening element between the element and another element.

[0034] The terms used in the various exemplary versions or embodiments of the present disclosure are for the purpose of describing specific exemplary versions or embodiments only and are not intended to limit various exemplary versions or embodiments of the present disclosure. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise. Use of dimensions, temperatures, ranges, time, relationships (e.g., “perpendicular”, “parallel”), etc. that either use or do not use further adjectives such as “generally”, “substantially”, “about” or “approximately” in the description or claims are intended to cover both the specific dimension, temperature, range, time, relationship, etc., as well as a range ofequivalents (function, way, or result) and only intended to be limited by teachings of the prior art.

[0035] The terms used in the various exemplary versions or embodiments of the present disclosure are for the purpose of describing specific exemplary version or embodiments only and are not intended to limit various exemplary versions or embodiments of the present disclosure. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0036] All of the terms used herein including technical or scientific terms have the same meanings as those generally understood by an ordinarily skilled person in the related art unless they are defined otherwise. The terms defined in a generally used dictionary should be interpreted as having the same meanings as the contextual meanings of the relevant technology and should not be interpreted as having inconsistent or exaggerated meanings unless they are clearly defined in the various exemplary embodiments.

[0037] Referring to Figures 2 - 4, there is shown a vehicle component 100 formed from an unsupported extruded profile body and having a bent region in a portion thereof. More specifically, and without limiting the present disclosure, the unsupported extruded profile broadly refers to any unsupported extruded component that needs to be bent to a sharp radius and that is overmolded, and the component can be used at any location on a vehicle. For example, this process can apply to a wide variety of seal assemblies, that is, seal assemblies that include a rigid polymer gripper region (such as a rigid polypropylene (PP) or thermoplastic vulcanizate (TPV) -- a more rigid polymer gripping portion - of the seal assembly, and the rigid polymer region requires a heat bending step to configure the component) that is often associated with an outer waist belt seal assembly, inner waist belt seal assembly, etc. Likewise, the process may find application in connection with a hood seal that includes a rigid gripping region.

[0038] In this particular instance, the exemplary vehicle component 100 is a vehicle seal assembly or glassrun seal assembly associated with a vehicle door (e.g., a front door - not shown). The seal assembly 100 includes first and second generally vertical portions 102, 104 that extend in linear fashion at front and rear ends of the door. 1stor upper ends 106, 108 are joined to a header portion 120. In this particular example, theheader portion 120 extends forwardly of the front vertical portion 102 in a region denoted by reference numeral 122 and also rearwardly of the rear vertical portion 104 in a region noted by reference numeral 124. The vertical portions 102, 104 and a central portion 126 of the header portion 120 between the vertical portions is profiled as a part of the manufacturing process to include one or more seal lips that are oriented for abutting, sealing engagement along perimeter edges of a door window (not shown) that is selectively raised and lowered relative to the seal assembly 100.

[0039] Select areas of the seal assembly 100 include molded structures / molded portions for interconnecting portions of the seal assembly, and / or conforming, sealed engagement with adjacent regions of the vehicle. For example, and without unduly limiting the present disclosure, these molded portions include interconnecting molded corners 130, 132 that join respective upper ends vertical portions 102, 104 to the header portion 120. The molded portions also include sealed interface regions 134 and 136 at the front and rear terminal ends of the header portion 120.

[0040] Notably, the central portion 126 of the header portion 120 is bent along at least part of its length between the corners 130, 132. Rather than providing for a separate bending operation and a separate insertion of the bent body into a mold cavity in order to overmold a fill member in a notch of the bent body as described in connection with Figure 1 , the present disclosure achieves the configuration shown in Figures 2 - 4 by both hot bending and injection molding to form the fill member in a mold cavity. As will be appreciated, a linear, unsupported (i.e., no reinforcement carrier) extruded profile body 140 includes a notch 142 formed therein. The notched body 140 is inserted into a mold cavity denoted in broken lines by reference numeral 144 where both hot bending 146 of the body and injection molding 148 of fill material to form a fill member 150 are completed to provide a bent, vehicle component 160 that includes the injection molded fill member 150.

[0041] Combining both of these method steps 146, 148 in the mold cavity 144 provides a number of advantages over the prior art manufacturing method represented in Figure 1 . For example, the present method of Figure 4 is an improvement over the prior arrangement since it is easier to load a linear body 140 into the mold cavity than a curved body. Further, processing time is improved since both the hot bending step 146and the injection molding step 148 occur in the mold cavity 144. There is no need to wait for the hot bent body to at least partially cure before transfer into a mold cavity for subsequently injection molding / overmolding the fill member as occurred in the process of Figure 1 ; rather, the hot bending 146 and injection molding / overmolding 148 to create a bent vehicle component 160 that includes overmolded fill member 150 is achieved in a single mold cavity 144. The combined hot bending and overmold process of the unsupported extruded profile advantageously results in the ability to maintain a sharper radius than prior arrangements that attempt to avoid molding or avoid the heat bending.

[0042] The hot bending 146 and molding 148 steps are done at least partially simultaneously. Extruded, notched linear bodies 140 can be manufactured just prior to the combined hot bending 146 and injection molding 148 process steps, or the bodies 140 can be separately manufactured well in advance of this additional steps that occur in the mold cavity 144. As is also evident in Figures 2 - 4, the body 140 is oriented so that the notch 142 is located within an angle that is either acute or obtuse between the first and second ends of the resultant bent body. Post bending, the sidewalls of the notch are angled toward and brought closer to one another.

[0043] Preferably, the fill material that is injection molded / overmolded into the notch 142 of the body 140 is preferably the same general material as that portion of the body in which the notches formed. In this manner, the fill member 150 securely bonds with the remainder of the body and assists in maintaining the bent configuration of the hot bent body. That is, the notch 142 facilitates the hot bending 146 and once the fill material is at least partially cured, the fill member 150 contributes to maintaining the bent configuration of the vehicle component 160. For example, a thermoplastic elastomer (TPE) or a thermoplastic vulcanizate (TPV) are commonly used materials in vehicle components of this type, although still other materials can be used without departing from the scope and intent of the present disclosure in reference to this commonly used material should not be deemed limiting. While using the same general material, it will also be appreciated that one or more desired physical properties of the same material can be achieved, for example if different durometers of the body and fill member 150 are desired.

[0044] This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. Other examples that occur to those skilled in the art are intended to be within the scope of the invention if they have structural elements that do not differ from the same concept or that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the same concept or from the literal language of the claims. Moreover, this disclosure is intended to seek protection for a combination of components and / or steps and a combination of claims as originally presented for examination, as well as seek potential protection for other combinations of components and / or steps and combinations of claims during prosecution.

[0045] Although specific advantages have been enumerated above, various embodiments may include some, none, or all of the enumerated advantages. Although exemplary embodiments are illustrated in the figures and description herein, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components, and the methods described herein may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.

[0046] To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 USC 112 (f) unless the words “means for” or “step for” are explicitly used in the particular claim.

Claims

What is claimed is:

1. A method of manufacturing a vehicle component comprising: providing a body having an extruded profile formed at least in part from a material and a notch formed through a portion of the body; placing the body with the extruded profile having a notch formed therein into a mold cavity; and in the mold cavity, both (i) bending the body at a temperature less than a melting temperature of the material from a first, linear conformation to a second, bent configuration and (ii) molding a fill member into the notch of the bent body from one of the same or a different material that will join with the body material.

2. The method of claim 1 wherein the bending and molding steps are done at least partially simultaneously.

3. The method of claim 1 wherein the providing step includes supplying the body without a reinforcement carrier.

4. The method of claim 1 wherein the providing step includes initially extruding the body into a desired profile.

5. The method of claim 4 wherein the extruding step does not include a reinforcement carrier.

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

7. The method of claim 6 wherein the body orienting step locates the notch in an obtuse angle between the first and second ends of the bent body.

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

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

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

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

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

13. The method of claim 1 further comprising forming a fill member with a fill member material that is different than the body material, the body material and the fill member material defining an integral structure when cured together.

14. The method of any one of claims 1 - 13 wherein the method of manufacturing a vehicle component includes manufacturing a header portion of a window seal assembly for an associated vehicle.

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