A sealing carrier

Abstract

The invention relates to a sealing carrier. The invention particularly relates to a seal carrier for sealing a gap between an opening frame of a vehicle such a door and the vehicle body.

Description

[0001] A SEALING CARRIER

[0002] Technical Field

[0003] The invention relates to a sealing carrier.

[0004] The invention particularly relates to a sealing carrier for sealing a gap between an opening frame of a vehicle such a door and the vehicle body.

[0005] State of the Art

[0006] Dynamic and static seals play crucial roles in ensuring the performance, safety, and comfort of automotive vehicles. Dynamic seals are components that maintain a seal between two surfaces that are in relative motion. In automotive applications, these seals are typically mounted onto the car frame and interact with moving parts such as doors. They prevent fluids like water from leaking in and keep dust, dirt, and other contaminants from entering the vehicle. Additionally, they reduce noise by sealing gaps between moving parts and help dampen vibrations that occur due to the movement of the doors. These seals are commonly made from elastomers due to their flexibility and durability. Thermoplastic elastomers (TPEs), which combine the properties of plastics and rubber, are also used for their flexibility and resilience. The design of dynamic seals can vary, including lip seals with a flexible lip that maintains contact with the moving surface.

[0007] Static seals, on the other hand, maintain a seal between two surfaces that do not move relative to each other. In automotive applications, these seals are typically mounted onto the car doors. They prevent fluids and contaminants from entering the vehicle, help maintain the internal temperature by sealing gaps, and block external noise from entering the cabin. Common materials for static seals include rubber, particularly EPDM for its weather-resistant properties.

[0008] Modern automotive design utilizes static seals in various applications, including sealing door frames to ensure no gaps for air or water to enter, sealing hatchbacks to prevent dust and water ingress, and sealing trunks to keep them secure. Innovations in this field include the development of aerodynamic designs that minimize air resistance and improve fuel efficiency, the use of lightweight materials to reduce the vehicle's overall weight, and the creation of seals with improved resistance to UV radiation, ozone, and extreme temperatures.

[0009] In summary, dynamic and static seals are essential components in modern vehicles, contributing to performance, comfort, and safety. Continuous advancements in materials and manufacturing processes are driving improvements in seal performance and longevity.

[0010] Dynamic seals in automotive applications typically use a U-form carrier design. This design is effective because it can accommodate the necessary insertion and extraction forces through its inner lips, which provide the required grip and sealing function when the seal is installed onto the car frame or door. However, achieving the target insertion and extraction forces can be challenging, particularly when there are variations in the thickness of the flange, which is the part of the car frame or door where the seal is attached. Larger variations in flange thickness can result in inconsistent performance of the seal, as the lips may not provide uniform pressure and grip.

[0011] Dynamic seals can be made from various materials, including thermoplastics (TP) and elastomers like EPDM. Thermoplastic materials are used for their ease of manufacturing and certain performance benefits, but they also come with their own set of challenges. The manufacturing process for thermoplastic dynamic seals imposes certain design restrictions, particularly due to the behaviour of the material when it is moulded and cooled. The die design must account for these material properties to ensure consistent production quality.

[0012] Permanent set is a measure of how much a material deforms under pressure and does not return to its original shape. Thermoplastics generally have a poorer permanent set behaviour compared to elastomers like EPDM. This means that after being compressed, thermoplastic lips may not return to their original shape effectively, leading to poor sealing performance over time. Due to this poor permanent set behaviour, the lips on these seals may not maintain sufficient pressure against the flange to ensure a secure and effective seal. This can lead to difficulties in maintaining the profile (shape and position) of the seal, reducing its overall performance and reliability.

[0013] In previous designs, the carrier of dynamic seals often featured an oblique lip forming non return hook. This design aims to provide the specified forces required for mounting and removing the seal. However, due to variations in flange thickness and the material properties of thermoplastics, this approach did not always meet performance specifications. EPDM (ethylene propylene diene monomer) is an elastomer with better permanent set behaviour compared to thermoplastics. It can return to its original shape more effectively after compression, making it more reliable for maintaining the seal profile and performance. Thermoplastic materials do not perform as well as EPDM in this regard.

[0014] To compensate for the poor permanent set behaviour and ensure the seal remains in place, additional hooks or notches may need to be stamped onto the vehicle steel flange when using thermoplastic materials. These hooks help secure the seal but add complexity and cost to the vehicle manufacturing process. In summary, while U-form carrier designs are common in dynamic seals, achieving the necessary insertion and extraction forces with lip designs can be challenging, especially with variations in flange thickness. Thermoplastic materials pose additional difficulties due to their poor permanent set behaviour, necessitating design modifications such as additional hooks to maintain seal performance. EPDM, with its better permanent set behaviour, often provides superior performance in these applications.

[0015] As a result of the search related to the subject, US20130180179A1 and US20130055644A1 have been found. These applications relate to bendable thermoplastic reinforcements, in particular for a profiled seal or profiled trim moulding of a motor vehicle, such a profiled element comprising the reinforcement, and a method for the production of said reinforcement. The inventions relate, in particular, to such profiled elements which are capable of being fixed to a rebate of a frame and which form lateral or front / rear opening seals for motor vehicles of the tourism, utility or heavy goods type, such as for example side door entry seals, seals for the trunk, tailgate or swinging rear door, hood seals, sliding seals possibly of the internal semi-sliding type, single-rebate type or truck style type, double sealing gaskets, rear wheel housing seals or dirt-resistant seals.

[0016] In conclusion, it has been required to make an improvement in the related technical field due to the above-mentioned drawbacks and the inadequacy of the present solutions about the subject. Object of the Invention

[0017] The invention is inspired by the present conditions and aims to solve the above- mentioned disadvantages.

[0018] The invention aims to address multiple challenges associated with dynamic seals, particularly focusing on achieving the required insertion and extraction forces and maintaining effective sealing performance across varying flange thicknesses. The primary goal is to ensure that dynamic seals can be easily mounted onto flanges with the appropriate insertion force and securely held in place with the required extraction force, thus maintaining the integrity and functionality of the seal. Traditional designs rely on inner lips to achieve the necessary grip and sealing function, but this invention proposes a new carrier design that eliminates the need for inner lips, which can be difficult to manufacture, especially for thermoplastic (TP) seals due to material properties.

[0019] The invention seeks to provide a sealing solution that can easily adapt to varying flange thicknesses, which is particularly challenging in traditional designs where large variations in flange thickness can make it difficult to achieve the target forces with lip designs. By eliminating the inner lips, the invention simplifies the manufacturing process for dynamic seals, especially for TP materials, addressing the technical and mechanical property restrictions that make the production of inner lips challenging.

[0020] Moreover, the invention incorporates a special geometry that allows seals to be mounted and meet the required forces for both mounting and removal, enhancing the reliability and performance of the dynamic seals. The clip carrier in this design can be made from various materials such as polypropylene (PP), steel, aluminium, or equivalent materials, providing flexibility in material choice based on specific application requirements.

[0021] One of the significant challenges for TP door seals has been their poor permanent set behaviour, which affects the insertion and extraction forces. The new design overcomes these issues, ensuring better performance of TP seals. For the EPDM version, the postforming process (conformation at the end of the extrusion process) of the seal can be easier and more effective with the invention’s design geometry, improving manufacturing efficiency.

[0022] Additionally, the invention aims to improve the removal force of seals from flanges without the need for additional hooks or retention mechanisms on the sheet metal or flange. This simplifies the assembly process and reduces the complexity and cost associated with manufacturing and installing these seals.

[0023] In summary, the invention not only aims to achieve the required insertion and extraction forces and adapt to varying flange thicknesses but also eliminates the need for inner lips in both TP and EPDM seals, simplifies manufacturing processes, incorporates flexible material options for the carrier, addresses the poor permanent set behaviour of TP materials, enhances post-forming processes for EPDM seals, and improves the removal force without additional retention mechanisms.

[0024] In order to achieve the objects described above, the invention relates to a sealing carrier (A) for sealing a gap between an opening frame of a vehicle such a door and the vehicle body, comprising:

[0025] • a main portion in a strip form,

[0026] • at least one first leg on a side of the main portion, wherein the first leg comprises: o a transverse portion which is connected to the main portion, o a longitudinal portion which is connected to the transverse portion and o a slight curve on the longitudinal portion,

[0027] • at least one second leg on other side of the main portion, wherein the second leg comprises: o a transverse portion of which longer portion is connected to the main portion and o a C portion which is connected to the shorter portion of the transverse portion,

[0028] • gaps between each first legs and also between each second legs, wherein the gaps are positioned in such a way that the gaps on each side of the main portion never faces each other, wherein a space is created between the main portion, the first legs and the second legs, wherein a steel flange of the vehicle is inserted into, the first leg behaves as a surface which the steel flange leans on, and the second leg behaves as a pressing force applier onto the steel flange so that the steel flange stays inside the sealing carrier. The structural and characteristic features of the invention and all of its advantages will be understood more clearly by means of the figures given below and the detailed description written with reference to these figures, and therefore, the evaluation needs to be carried out by taking these figures and detailed description into consideration.

[0029] Drawings For Better Understanding of The Invention

[0030] Figure 1 shows a carrier used in prior art.

[0031] Figure 2 shows isometric view of sealing carrier of the invention.

[0032] Figure 3a shows B-B section view of the sealing carrier.

[0033] Figure 3b shows C-C section view of the sealing carrier.

[0034] Figure 4 shows top view of the sealing carrier.

[0035] Figure 5 shows forces applied on the sealing carrier

[0036] Figure 6 shows the first embodiment of the invention.

[0037] Figure 7 shows the second embodiment of the invention.

[0038] Figure 8 shows the third embodiment of the invention.

[0039] Description of the References

[0040] 10 Main portion

[0041] 20 First leg

[0042] 21 Transverse portion

[0043] 22 Longitudinal portion

[0044] 23 Curve

[0045] 30 Second leg

[0046] 31 Transverse portion

[0047] 32 C portion

[0048] 40 Gap

[0049] A Sealing carrier

[0050] S Steel flange

[0051] PF Pressing force

[0052] RF Removal force

[0053] AF Assembly force

[0054] 100 Carrier used in prior art

[0055] 101 Lips used in prior art 200 TPE-1 or slip coating

[0056] 201 TPE-2

[0057] 202 TPE-3

[0058] 203 TPE-4

[0059] 300 Slip coating

[0060] 301 Cellular EPDM

[0061] 302 Compact EPDM

[0062] 303 Micro dense EPDM

[0063] 304 Surface (Compact EPDM)

[0064] 400 Glass fiber rope

[0065] Detailed Description of the Invention

[0066] In this detailed description, preferred embodiments of sealing carrier (A) of the invention are described only for a better understanding of the subject.

[0067] Figure 1 shows a carrier used in prior art (100), which has U form and lips (101 ) on the internal walls of the carrier. The sealing carrier (A) eliminates requirement for the lips (101 ).

[0068] Figure 2 shows isometric view of the sealing carrier (A) which comprises a main portion (10) in a strip form. There are at least one first leg (20) on a side of the main portion (10) and at least one second leg (30) on other side of the main portion (10). The main portion (10), the first leg (20) and the second leg (30) are in a monolithic form.

[0069] The first leg (20) comprises a transverse portion (21 ) which is connected to the main portion (10) and a longitudinal portion (22) which is connected to the transverse portion (21 ). The transverse portion (21 ) and the longitudinal portion (22) are in a monolithic form. There is a slight curve (23) on the longitudinal portion (22). Details of the first leg (20) is shown on Figure 3a.

[0070] The second leg (30) comprises an transverse portion (31 ), of which longer portion is connected to the main portion (10) and a C portion (32) which is connected to the shorter portion of the transverse portion (31 ). The transverse portion (31 ) and the C portion (32) are in a monolithic form. Details of the second leg (30) is shown on Figure 3b.

[0071] There are gaps (40) between each first legs (20) and also between each second legs (30). The gaps (40) are positioned in such a way that the gaps (40) on each side of the main portion (10) never faces each other. Accordingly, the first legs (20) and the second legs (30) also do not face each other. The positioning of the main portion (10), the first legs (20), the second legs (30) and the gaps (40) are shown in Figure 4.

[0072] According to the invention, a space is created between the main portion (10), the first legs (20) and the second legs (30), wherein a steel flange (S) of a vehicle is inserted into. The first leg (20) behaves as a surface which the steel flange (S) leans on, and the second leg (30) behaves as a pressing force applier onto the steel flange (S) so that the steel flange (S) stays inside the sealing carrier (A). The curve (23) of the first leg (20) and arc form of the C form (32) of the second leg (30) have almost same radius so that when the steel flange (S) is not inserted into the sealing carrier (A), the C form (32) may place in the curve (23).

[0073] The surface (304) of the C form (32) which touches the steel flange (S) is with high friction coefficient material so that a better retention is obtained.

[0074] Pressing force (PF), removal force (RF) and assembly force (AF) applied on the sealing carrier are shown in Figure 5.

[0075] The use of the sealing carrier (A) is described as follows:

[0076] Figure 6 shows the first embodiment of the invention, wherein the sealing carrier (A) is made of polypropylene (PP) and covered in a single step co-extrusion process by a TPE- 4 (203), making general coverage, a TPE-3 (202), making junction arm to connect with a TPE-2 (201 ) which is in a form of tube / bulb. A slip coat or a TPE-1 (200) can cover the tube / bulb (201 ) There is a glass fiber rope (400) on the internal part of the TPE-4 (203) for process stability.

[0077] Figure 7 shows the second embodiment of the invention, wherein the sealing carrier (A) is made of steel or aluminium. The features of the second embodiment are same as the first embodiment except material of the sealing carrier.

[0078] TPEs refer to thermoplastic elastomers that can include TPV referring to thermoplastic vulcanizates

[0079] Figure 8 shows the third embodiment of the invention, wherein the sealing carrier (A) is made of steel or aluminium and covered in a single step co-extrusion process by a micro dense EPDM (303), making general coverage, a compact EPDM (302), making junction arm to connect with a cellular EPDM (301) which is in a form of tube / bulb. A slip coat (300) can cover the tube / bulb (301 ) There is a glass fiber rope (400) on the internal part of micro dense EPDM (303) for process stability. A compact EPDM (304), having high grip properties, can cover C portion (32) of leg (30). EPDM (303) and EPDM (304) can be also the same material.

[0080] EPDM refers to ethylene propylene diene monomer.

Claims

CLAIMS1. A sealing carrier (A) for sealing a gap between an opening frame of a vehicle such a door and the vehicle body, characterized by comprising:• a main portion (10) in a strip form,• at least one first leg (20) on a side of the main portion (10), wherein the first leg (20) comprises: o a transverse portion (21 ) which is connected to the main portion (10), o a longitudinal portion (22) which is connected to the transverse portion (21 ) and o a slight curve (23) on the longitudinal portion (22),• at least one second leg (30) on other side of the main portion (10), wherein the second leg (30) comprises: o a transverse portion (31 ), of which longer portion is connected to the main portion (10) and o a C portion (32) which is connected to the shorter portion of the transverse portion (31 ),• gaps (40) between each first legs (20) and also between each second legs (30), wherein the gaps (40) are positioned in such a way that the gaps (40) on each side of the main portion (10) never faces each other, wherein,- a space is created between the main portion (10), the first legs (20) and the second legs (30), wherein a steel flange (S) of the vehicle is inserted into,- the first leg (20) behaves as a surface which the steel flange (S) leans on, and the second leg (30) behaves as a pressing force applier onto the steel flange (S) so that the steel flange (S) stays inside the sealing carrier (A).

2. The sealing carrier (A) according to claim 1 , characterized in that the main portion (10), the first leg (20) and the second leg (30) are in a monolithic form.

3. The sealing carrier (A) according to claim 1 or 2, characterized in that the transverse portion (21 ) and the longitudinal portion (22) are in a monolithic form.

4. The sealing carrier (A) according to any of the preceding claims, characterized in that the transverse portion (31 ) and the C portion (32) are in a monolithic form.

5. The sealing carrier (A) according to any of the preceding claims, characterized in that the curve (23) of the first leg (20) and arc form of the C form (32) of the second leg (30) have almost same radius so that when the steel flange (S) is not inserted into the sealing carrier (A), the C form (32) may place in the curve (23).

6. The sealing carrier (A) according to any of the preceding claims, characterized in that the surface of the C form (32) which touches the steel flange (S) is covered with high friction coefficient material skin for obtaining retention.

7. A TPE-1 or slip coating (200) characterized by comprising:• a TPE-4 (203) surrounds the sealing carrier (A) according to claims 1 to 6, wherein the sealing carrier (A) placed in a TPE-1 or slip coating (200),• a TPE-2 (201 ), which in a form of tube / bulb material,• a TPE-3 (202) making junction arm to connect with a TPE-2 (201 ) wherein the TPE-2 (201 ) and TPE-3 (202) are connected to the TPE-4 (203) and each other,• a glass fiber rope (400) on the internal part of the TPE-4 (203) for process stability.

8. The TPE-1 or slip coating (200) according to claim 7, characterized in that the sealing carrier (A) is made of polypropylene (PP).

9. The TPE-1 or slip coating (200) according to claim 7, characterized in that the sealing carrier (A) is made of steel or aluminium.

10. A slip coating (300) characterized by comprising:• a micro dense EPDM (303) surrounds the sealing carrier (A) according to claims 1 to 6, wherein the sealing carrier (A) placed in a slip coating (300),• a cellular EPDM (301 ), which in a form of tube / bulb material,• a compact EPDM (302), which is needed for general coverage, wherein the cellular EPDM (301 ) and the compact EPDM (302) are connected to the micro dense EPDM (303) and each other,• a glass fiber rope (400) on the internal part of the micro dense EPDM (303) for process stability.

11. The slip coating (300) according to claim 10, characterized in that the sealing carrier (A) is made of steel or aluminium.5

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