System and method for application of a vehicle seal and bonding material to a vehicle component

Abstract

A method and system for application of a vehicle seal to a surface of a component uses an adhesive application device having a first applicator and a first spool and a seal application device having a second applicator and a second spool. The method includes winding a bonding material onto the first spool where the bonding material is a thermoplastic rubber-based pressure sensitive adhesive. The method also includes winding a vehicle seal onto the second spool where the vehicle seal includes a bonding surface. The method also includes softening the bonding material through the first applicator while simultaneously unwinding the bonding material from the first spool, applying the softened bonding material onto the surface of the component in a desired pattern, and applying the bonding surface of the vehicle seal onto the bonding material in the desired pattern while simultaneously unwinding the vehicle seal from the second spool.

Description

SYSTEM AND METHOD FOR APPLICATION OF A VEHICLE SEAL AND BONDING MATERIAL TO A COMPONENT OF A VEHICLECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and all the benefits of U.S. Provisional Patent Application No. 63 / 706,985, filed on October 14, 2024, the contents of which are hereby expressly incorporated herein by reference in their entirety.FIELD OF THE DISCLOSURE

[0002] The disclosure generally relates to a system and method for application of a vehicle seals to a vehicle, and, more particular, to the application of a vehicle seal and a bonding member to a vehicle.BACKGROUND OF DISCLOSURE

[0003] Vehicle seals (or sealing members), such as weatherstrips, in vehicles provide a seal between various parts to prevent water, dust, and air from entering the vehicle. Such sealing members, including the weatherstrips, for use with a vehicle are also commonly referred to as vehicle seals, and the terms may be referred to interchangeably herein. Traditionally, such vehicle seals are attached to components using mechanical means. The vehicle seals can also be attached through the use of adhesive tapes having tape liners. Generally, these adhesive tapes are double sided tapes. This tape-on method can have drawbacks, such as contamination leading to compromised adhesion and difficulty when used in corners. Further, the manual removal of the tape liner and the subsequent assembly of the vehicle seal to the vehicle introduces additional manufacturing complexity and additional equipment.1Attorney Docket No. 065517.01022

[0004] These related art methods are characterized by one or more inadequacies.Accordingly, it would be advantageous to provide a system and method that overcomes these inadequacies.SUMMARY OF THE DISCLOSURE

[0005] A method for application of a vehicle seal to a surface of a component uses an adhesive application device having a first applicator and a first spool and a seal application device having a second applicator and a second spool. The method includes winding a bonding material onto the first spool where the bonding material is a thermoplastic rubberbased pressure sensitive adhesive. The method also includes winding a vehicle seal onto the second spool where the vehicle seal includes a bonding surface. The method also includes softening the bonding material through the first applicator while simultaneously unwinding the bonding material from the first spool, applying the softened bonding material onto the surface of the component in a desired pattern, and applying the bonding surface of the vehicle seal onto the bonding material in the desired pattern while simultaneously unwinding the vehicle seal from the second spool.

[0006] A corresponding system includes the adhesive application device having the first applicator and the first spool and the seal application device having the second applicator and the second spool and applies the bonding material and the vehicle seal in accordance with the method as described above.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Other advantages of the present disclosure 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.

[0008] Figure 1 is a side view of a vehicle having a door trim assembly.2Attorney Docket No. 065517.01022

[0009] Figure 2 is a sectional view of a vehicle seal of the door trim assembly.

[0010] Figure 3 is a sectional view of a bonding material of the door trim assembly.

[0011] Figure 4 is a cross-sectional view of one embodiment of the invention taken along line 4-4 of Figure 1.

[0012] Figure 5 is a cross-sectional view of a second embodiment of the invention taken along line 5-5 of Figure 1.

[0013] Figure 6 is a cross-sectional view of a third embodiment of the invention taken along 6-6 of Figure 1.

[0014] Figure 7 is a schematic view of a portion of a system including an adhesive application device for dispensing the bonding material to a component.

[0015] Figure 8 is a schematic view of another portion of the system including a seal application device for disposing the vehicle seal onto the bonding material.

[0016] Figure 9 is a perspective view of the component having the vehicle seal and bonding material applied thereto using the adhesive application device of Figure 7 and the seal application device of Figure 8.

[0017] Figure 10 is a perspective view of a battery box prior to application of a bonding member and a vehicle seal.

[0018] Figure 11 is a perspective view of the battery box having the vehicle seal adhered thereto with the bonding material.

[0019] Figure 12 is a cross-sectional view of the battery box including the vehicle seal and bonding material adhered thereto coupled to a second component.3Attorney Docket No. 065517.01022DETAILED DESCRIPTION

[0020] Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a system 25 and method for application of a vehicle seal 40 and a bonding material 60 to a component 90 of a vehicle 20 is shown. In various embodiments below, and particularly as shown in three exemplary embodiments in Figures 4-6, the component 90 is a component used in a door trim assembly 30 of the vehicle 20. In another exemplary embodiment, as shown best in Figure 12, the component 90 is a battery box 150 used in the vehicle 20.

[0021] The vehicle seal 40, sometimes alternatively referred to as a sealing member 40, may include a weatherstrip, such as those formed from rubber, ethylene-propylene-diene- monomer (EPDM), Santoprene® thermoplastic elastomer (TPE) and the like. The vehicle seal 40 can include a portion formed of a cellular or sponge EPDM having a lower density and rigidity or any combination of materials. In addition, the vehicle seal 40 can be any suitable hardness or hardnesses, rigidity or rigidities, density, or densities, etc.

[0022] A cross-sectional view (i. e. , profile) of one example of the vehicle seal 40 is shown in Figure 2 configured for use as part of a door trim assembly 30 of a vehicle 20 as shown in Figure 1. It is to be appreciated that any number of seal profiles or configurations are suitable for use in this disclosure.

[0023] The vehicle seal 40, as shown in Figure 2 includes a bulb 42 defining an opening 44 therewithin. The vehicle seal 40 also includes a flange 46 extending from the bulb 42, with a gap 48 defined between the bulb 42 and the flange 46. The bulb 42, in certain embodiments, may include a nodule 50 that is positioned adjacent to a terminal end 52 of the flange 46. The flange 46 has a length LI that is defined between the terminal end 52 and a non-terminal end 54 with the non-terminal end 54 corresponding to the intersection of the4Attorney Docket No. 065517.01022flange 46 and bulb 42. In certain other embodiments, such as shown in Figure 12, the vehicle seal 40 may include a bulb 42 without a flange 46. As noted above, the vehicle seal40 may be of any suitable configuration.

[0024] The vehicle seal 40 also includes a bonding surface 56 that is applied to the bonding material 60 utilizing a seal application device 130 (see Figure 8) as described below. The bonding surface 56 refers to an outer surface of the vehicle seal that is brought into contact and adherence with the bonding material 60 when the door trim assembly 30 is complete and placed into the vehicle 20, as described below.

[0025] The bonding material 60, shown in one example in Figure 3, includes a first surface 62 and an opposing second surface 64 that define a core 66 therebetween. The first surface 62 is configured to receive the bonding surface 56 of the vehicle seal 40 thereon and the second surface 64 is configured to be positioned adjacent to the vehicle component 90 such that the bonding material 60 is disposed between the vehicle seal 40 and the component 90.

[0026] The bonding material 60 is preferably a thermoplastic rubber-based pressure sensitive adhesive. Being thermoplastic in nature, the bonding material 60 is capable of being deformed or becoming more viscoelastic in nature when heated to a temperature above its softening temperature (including during an extrusion process where pressure is also increased), while returning to a less deformable and less viscoelastic in nature when cooled to a temperature at or below its softening temperature while retaining its original physical properties and chemical structure. In particular, the softening temperature refers to a temperature at which the bonding material 60 begins to deform or soften, typically under heat and pressure such as when being extruded, from an initial softness to a desired softness. The softness of the bonding material 60, and hence the softening temperature of the5Attorney Docket No. 065517.01022bonding material 60, can be measured using standardized tests such as the VICAT SofteningTemperature (ASTM D1525) and Heat Deflection Temperature (ASTM D648).

[0027] The bonding material 60 is typically provided in filament form, i.e., as a continuous tape, and is applied onto a surface 92 of a component 90, such as a top surface 92 or outer surface 92 of the component 90, using an adhesive application device 120 (see Figure 7) as described below.

[0028] One commercially available pressure sensitive adhesive which is extrudable and is suitable for use as the bonding material 60 is 3M™ VHB™ (Very High Bond) Extrudable Tape, which is described by 3M as a durable, viscoelastic acrylic adhesive provided in filament form. Even more particularly, the 3M™ VHB™ (Very High Bond) Extrudable Tape is described as being made with an acrylic foam core 66 which is viscoelastic in nature, with certain families of the commercially available bonding material products further described as including a multi-purpose acrylic adhesive on both the top side 62 and the bottom side 64 of the conformable adhesive foam core 66.

[0029] The bonding material 60 may be provided in a filament form and is preferably provided rolled onto a spool 122 or reel of an adhesive application device 120 (see Figure 7 below) such that the bonding material 60 is dispensed onto the component 90 in a continuous manner. The bonding material 60, when rolled onto the spool 122 or reel, preferably does not include a liner.

[0030] Once applied to a surface 92 of the component 90, the bonding material 60 is configured to provide a strong adhesive bonding force to the surface 02 of the component 90 in a first direction towards the component 90 (i.e., transverse or orthogonal to the length of the surface 02 of the component 90), but wherein the lap shear strength in a direction transverse to the first direction is weaker to allow the bonding material 60 to be easily6Attorney Docket No. 065517.01022removed from the component by applying a force in a second direction transverse to the first direction.

[0031] Referring to Figures 4-6, three exemplary embodiments of the door trim assembly 30 of the vehicle 20 of Figure 1 and including the bonding material 60 and vehicle seal 40 are provided herein that are used to provide a seal between various door trim assembly components. Figure 12 also provides an additional exemplary embodiment of a battery box 150 including the bonding material 60 and vehicle seal 40 used to seal the battery box 150 to an second component 180, shown in Figure 12 as a body panel 180.

[0032] In the exemplary embodiments of Figures 4-6, the door trim assembly 30 may include a body pillar outer panel 100, a trim panel 102, a body pillar reinforcement panel 104, and vehicle door 106 including a door inner panel 108 and a door garnish trim 110.

[0033] In the embodiment of Figure 4, the bonding material 60 is applied to the component 90, and more specifically in this example, to a portion of a surface of the body trim outer panel 100 (and hence the body trim outer panel 100 is also considered generically as the component 90 as described above). The component 90 also includes the body pillar reinforcement panel 104. The bonding surface 56 of the flange 46 is positioned onto the first surface 62 of the bonding material 60 such that the bonding material 60 is disposed between the vehicle seal and the component 90. In this embodiment, the component 90 is further defined as a first component 90, and a second component 102 is also provided. The second component 102 is preferably a trim panel 120. A portion of the trim panel 102 extends within the gap 48 between the flange 46 and the bulb 42 and applies a force to the flange 46 transverse to and against the first surface 62 of the bonding material 60 to retain the vehicle seal on the bonding material. In other words, the trim panel 102 provides increased adhesion forces between the bonding surface 56 of the flange 46 and the first7Attorney Docket No. 065517.01022surface 62 of the bonding material 60. In short, there is a sandwiching of the second component 102, flange of the vehicle seal 40, bonding material 60, and first component 90, which creates the necessary retention forces to assist in holding the vehicle seal 40 against the bonding material 60.

[0034] When the vehicle door 106 is closed the vehicle door 106 is positioned such that the door garnish trim 110 contacts the bulb 42. The compressive force on the bulb 42 by the door garnish trim 100 also may provide additional force of the bonding surface 56 of the flange 46 transverse to and against the first surface 62 of the bonding material 60. In addition, the transverse force applied to the first surface 62 of the bonding material 60 provides a force of the second surface 64 of the bonding material 60 transverse to the length of the portion of the body pillar outer panel 100, which increases the adhesion force between the second surface 64 of the bonding material 60 and the body pillar outer panel 100.

[0035] In the embodiment of Figure 5, the configuration of door trim components of the door trim assembly 30 is the same, with the exception wherein the body trim outer panel 102 is not included and is not inserted within the gap 48 between the bulb 42 and the flange 46. In this configuration, the bonding material 60 is applied to a portion of the body trim outer panel 100, which is supported from below by the body pillar reinforcement panel 104. The bonding surface 56 of the flange 46 is positioned onto the first surface 62 of the bonding material 60 such that the bonding material 60 and the portion of the body trim outer panel 100 are positioned between the flange 46 and the body pillar reinforcement panel 104. Finally, when the vehicle door 106 is closed the vehicle door 106 is positioned such that the door garnish trim 110 contacts the bulb 42 opposite the flange 46 and against the bulb 42 to provide a force transverse to the bulb 42 and provide sealing engagement between the bulb 42 and the door garnish trim 100. The compressive force on the bulb 42 by the door garnish8Attorney Docket No. 065517.01022trim 100 also may provide an additional force to the flange 46 transverse to and against the first surface 62 of the bonding material 60 to provide a sealing engagement between the bonding surface 56 of the flange 46 and the first surface 62 of the bonding material 60 and provide increased adhesion forces therefore between the bonding surface 56 of the flange 46 and the first surface 62 of the bonding material 60. In addition, the transverse force applied to the first surface 62 of the bonding material 60 provides a force of the second surface 64 of the bonding material 60 transverse to the length of the portion of the body pillar outer panel 100, which increases the adhesion force between the second surface 64 of the bonding material 60 and the body pillar outer panel 100.

[0036] In the embodiment of Figure 6, the bonding material 60 is applied to a portion of the component 90, which in this instance is the body pillar reinforcement panel 104 (which generically is considered the vehicle component 90 as described above). The component 90 in this embodiment continues to include the body trim outer panel 100. The bonding material 60 and component 90 (having both the portion of the body reinforcement panel 104, and a portion of the body trim outer panel 100) are each inserted within the gap 48. The bonding surface 56 of the flange 46, corresponding to the surface of the flange 46 adjacent to and interior of the gap 48, is positioned onto the first surface 62 of the bonding material 60 (which as shown in Figure 6 is below the second surface 64 of the bonding material 60 in orientation). In this embodiment, the component 90 is also known as a first component 90 and a second component 102 is provided. The second component 102 is preferably a trim panel 102. A portion of the trim panel 102 is positioned beneath and against an outer surface of the flange 46 such that the flange 46 is disposed between the portion of the trim panel 102 and the bonding material 60. Both embodiments of Figures 4 and 6 have the second component 102 engage a portion of the vehicle seal, but the engagement locations9Attorney Docket No. 065517.01022are different. In short, there is a sandwiching of the second component 102, flange of the vehicle seal 40, bonding material 60, and first component 90, which creates the necessary retention forces to assist in holding the vehicle seal 40 against the bonding material 60.

[0037] Finally, when the vehicle door 106 is closed the vehicle door 106 is positioned such that the door garnish trim 110 contacts the bulb 42 opposite the flange 46 and against the bulb 42 to provide a force transverse to the bulb 42 and provide sealing engagement between the bulb 42 and the door garnish trim 110. The second component 102 (trim panel) and the positioning of the first component 90 (body trim outer panel 100 and the body pillar reinforcement panel 104) within the gap 48 provides a transverse force against the second surface 64 of the bonding material 60. The trim panel 102 provides the transverse force against and to the surface of the flange 46 opposite the bonding surface 56, which is translated to the bonding surface of the flange 46 to provide a transverse force against the first surface 62 of the bonding material 60 to provide sealing engagement between the first surface 62 of the bonding material 60 and the bonding surface of the flange 46. Still further, the compressive force on the bulb 42 by the door garnish trim 100 when the vehicle door 106 is closed also may provide additional force of the flange 46 against the body trim panel 102.

[0038] In the exemplary embodiment of Figures 10-12, the bonding material 60 is applied to a top surface 152 of a first component 90, which is shown as the battery box 150, such that the second surface 64 is disposed adjacent to the top surface 152. The vehicle seal 40 is applied onto the first surface 62 of the bonding material 60 and includes a bulb 42 without a flange 46. A second component 180, shown in Figure 12 as a vehicle support structure 180 such as a body panel 180. The bulb 42 of the vehicle seal 40 is positioned into pressing contact with the body panel 180 to provide a transverse force to and against the bulb 42, and10Attorney Docket No. 065517.01022hence a sealing engagement between the support structure 180 and the bulb 42. The compressive force on the bulb 42 by the second component 180 also may provide additional force of the bonding surface 56 of the flange 46 transverse to and against the first surface 62 of the bonding material 60, which may enhance the adhesion forces between the bonding surface 56 of the flange 46 and the first surface 62 of the bonding material 60.

[0039] In each of the embodiments of Figures 4-6 and Figures 10-12, the bonding material 60 provides for increased sealing capability between the vehicle seal 40 and component 90.

[0040] Referring next to Figures 7 and 8, the system 20 and associated method for applying the vehicle seal 40 to component 90 utilizing the bonding material 60 is provided and includes an adhesive application device 120 and a seal application device 130

[0041] Referring first to Figure 7, the bonding material 60 is dispensed by unrolling the bonding material 60 from a spool 122 through an applicator 124 of the adhesive application device 120 and onto the outer surface 92 of the component 90 in a desired pattern 68.

[0042] Prior to dispensing, the bonding material 60 may be wound onto the spool 122. Preferably, the bonding material 60 is wound onto the spool 122 without a liner.

[0043] In the embodiment shown in Figure 7, the applicator 124 is mounted to a robotic arm 126 which moves with the applicator 124 in the x-direction and the y-direction in the desired pattern 68 along the outer surface 92 of the component 90 during the bonding material 60 application process. In alternative arrangements, the system 20 may be configured wherein a robotic arm 126 is not utilized, and instead the component 90 is configured to move in the x-direction and the y-direction in the desired pattern 68 while the applicator 124 remains stationary. Relatedly, in further alternative embodiments, the adhesive application device 120 is a handheld device, and the operator moves the applicator 124 in the x-direction and11Attorney Docket No. 065517.01022the y-direction in the desired pattern 68 along the outer surface 92 of the component 90 during the bonding material 60 application process.

[0044] The desired pattern 68 of application of the bonding material 60, in certain embodiments, is a closed loop and may be designed to generally correspond to the shape of the component 90. In the closed loop, the bonding material 60 may be applied wherein there are one or more comers 70 defining a transverse angular directional change between the lengths of adjacent portions 72, 74, of the bonding material 60 (see Figure 8). In embodiments including corners 70, the bonding material 60 is applied to the surface 92 of the component 90 through and around the one or more corners 70 in a continuous manner, preferably while simultaneously unrolling the bonding material 60 from the spool 122.

[0045] The bonding material 60 of the subject disclosure allows for precise robotic application, thus eliminating manual handling and potential contamination, misapplication, ensuring no gaps and meeting stringent water immersion requirements.

[0046] In the representative embodiment of Figure 9 (and as shown in Figure 11 on the battery box 150), the desired partem 68 is rectangular in shape, and the four corners 70 define a 90-degree angular transition between the first portion 72 and second portion 74. Other shapes of the closed loop 68 are specifically contemplated that include more or less comers 70 having varying transverse angular directional changes between the lengths of adjacent portions 72, 74, of the bonding material 60. In addition, a closed loop wherein no comers 70 are present is contemplated, including a circular-shaped desired pattern 68 or an oval-shaped desired pattern 68.

[0047] In certain embodiments, the applicator 124 warms the bonding material 60 to a first temperature as it is being forced (i.e., extruded) through a tip 128 of the applicator 124 and onto the outer surface 92. In particular, the applicator 124 warms the bonding material 60 to12Attorney Docket No. 065517.01022a first temperature greater than or equal to the softening temperature of the bonding material 60 as it is being forced through the tip 128 of the applicator 124 and onto the surface 02 of the component 90. The softening temperature of the bonding material 60 is known and thus the first temperature applied by the applicator 124 is sufficient to warm the bonding material 60 to the first temperature greater than or equal to the softening temperature as it is forced through the tip 128 under a specific load (here the load applied as the bonding material is forced through the tip 128). Accordingly, the bonding material 60 may be considered an extrudable bonding material 60.

[0048] One advantage of the bonding material 60 is that it can be removed from the outer surface 92 of the component 90 after application if the desired pattern 68 is not met by simply applying a force nearly parallel to the surface 92 of the component 90. This allows for easier removal if the application is inadequate, which also reduces unnecessary scrap. Further, the bonding material 60 allows for removal under certain forces at certain angles not parallel to the surface 92 of the component 90, the forces required to bond and secure the vehicle seal 40 to the outer surface 92 of the component 90 do not approach these needed for removal.

[0049] Referring next to Figure 8, the seal application device 130 is also illustrated as a robotic device in which a robotic arm 134 is shown having an applicator 132 for installing the vehicle seal 10. The robotic arm 134 could be the same as the robotic arm 126 used for dispensing the bonding material 60 with a different end-of-arm tool or it could be a different robotic arm such as illustrated in Figure 8. The vehicle seal 40 may be provided in a coil around a spool 138 or reel such that the vehicle seal 40 is dispensed in a continuous manner onto the bonding material 60. These types of seal (i.e., the vehicle seal 40) are known in the industry as endless seals. These endless seals are preferably extruded in a continuous13Attorney Docket No. 065517.01022manner prior to the application process provided herein and wound about the spool 138. The configuration and / or seal profile may be of any suitable type capable of continuous extrusion that can also be wound. The profile shown in Figure 2 is one such example of an endless seal.

[0050] In the seal application device 130 of Figure 8, the applicator 132 is mounted to the robotic arm 134 which moves with the applicator 132 in the x-direction and the y-direction along the outer surface 92 of the component 90 during the application process of the bonding surface 56 of the vehicle seal 40 onto the first surface 62 of the bonding material 60 in a desired pattern 168 (see Figures 8 and 9). The movement of the applicator 132 is preferably in the same desired pattern 168 as the movement as the applicator 124 in its desired pattern 68 to ensure that the vehicle seal 40 is applied onto the entirety of the previously applied bonding material 60. In alternative arrangements, the system 20 may be configured wherein a robotic arm 134 is not utilized, and instead the component 90 with the previously applied bonding material 60 is configured to move in the x-direction and the y- direction in the desired pattern 168 while the applicator 132 remains stationary. Relatedly, in further alternative embodiments, the seal application device 130 is a handheld device, and the operator moves the applicator 132 in the x-direction and the y-direction in the desired pattern 68 along the outer surface 92 of the component 90 during the application process for applying the vehicle seal 40 onto the bonding material 60.

[0051] The desired pattern 168 of application of the vehicle seal 40 onto the bonding material 60, in certain embodiments, is also a closed loop, and is preferably the same shape as the desired pattern 68 of the closed loop of bonding material 60, and also therefore may be designed to generally correspond to the shape of the component 90. In the closed loop, the bonding surface 56 of the vehicle seal 40 may be applied onto the first surface 62 of the14Attorney Docket No. 065517.01022bonding material 60 wherein there are one or more comers 170 defining a transverse angular directional change between the lengths of adjacent portions 172, 174, of the vehicle seal 40 (see Figures 8 and 9). In embodiments including corners 170, the vehicle seal 40 is applied onto the bonding material 60 through and around the one or more corners 170 in a continuous manner, preferably while simultaneously unrolling the vehicle seal 40 from the spool 138. In these embodiments, the comers 170 and adjacent portions 172, 174 of the vehicle seal 40 correspond in number and shape to the corresponding corners 70 and adjacent portions 72, 74 of the bonding material 60.

[0052] Referring back to Figure 8, the applicator 132 for installing the vehicle seal 40 may incorporate several motorized rollers 136 which allow the advancement of the vehicle seal 40 and pressurizing the vehicle seal 40 against the outer surface 92 of the component 90, and more in particular against the bonding material 60 previously applied onto the outer surface 92 of the component 90. The rollers 136 may also be designed to wet-out the vehicle seal 40 onto the bonding material 60, thereby providing increased surface area of contact between the vehicle seal 40 and the bonding material 60 to ensure a strong and consistent bond.

[0053] The applicator 132 for the seal application device 130 of Figure 8 also has a cutter (not shown) to cut the vehicle seal 40 at a desired length and with an appropriate angle so that starting and terminal ends are face to face without leaving play between these two ends. If desired, the vehicle seal 40 ends may be cut to a length to allow for overlap. In certain embodiments, the vehicle seal 40 is cut at an angle, to the correct length, by the cutter and the finished assembly results in an overlapped joint, also referred to as a butt-joint. The subject disclosure ensures there are no gaps that could lead to water leaks within the applied vehicle seal 40.15Attorney Docket No. 065517.01022

[0054] In certain embodiments, wherein the bonding material 60 is heated above its softening temperature during the bonding material application process, the application of the vehicle seal 40 onto the bonding material 60 occurs where the temperature of the bonding material 60 applied to the component 90 is greater than or equal to the softening temperature of the bonding material 60. The softened bonding material 60 may provide for increased adhesion between the bonding surface 56 of the vehicle seal 40 and the first surface 62 of the bonding material 60.

[0055] In other embodiments, wherein the bonding material 60 is heated above its softening temperature during the bonding material application process, the application of the vehicle seal 40 onto the bonding material 60 occurs where the temperature of the bonding material 60 applied to the component 90 is below the softening temperature of the bonding material 60. The bonding material 60 still provides sufficient adhesion between the bonding surface 56 of the vehicle seal 40 and the first surface 62 of the bonding material 60, particularly where the second component (such as the trim piece 102 in Figure 4 and the body panel 180 in Figure 12.

[0056] The final assembly shown in Figure 9 results in the component 90 with the fully attached vehicle seal 40 on the surface 92 of the component 90 via the extrudable bonding material 60.

[0057] In Figures 10- 11 , the same method described in the system of Figure 7 can be used to apply the bonding material 60 in the desired pattern 68 to the top surface 152 of the battery box 150, and the same method of Figure 8 can be used to apply the vehicle seal 40 onto the applied bonding material 60 in the desired pattern 168. The battery box 150 may then be mounted to the second component 180, shown as a body panel 180 in Figure 12,16Attorney Docket No. 065517.01022with the bulb sealingly engaged with the body panel 180 and with the bonding material 60 providing the seal between the bulb 42 and the battery box 150 as desired.

[0058] This subject disclosure ensures a high-quality, reliable seal that meets stringent water immersion requirements and eliminates common issues associated with traditional tape -on weatherstrip methods. By automating the process and using advanced materials, this disclosure significantly improves the reliability and performance of sealing material in vehicles, providing a robust solution to longstanding problems in the industry.

[0059] The subject disclosure addresses the aforementioned problems of the prior methods and allows for precise robotic application, thus eliminating manual handling and potential contamination, misapplication, ensuring no gaps, preventing water leaks, and meeting stringent water immersion requirements.

[0060] The disclosure 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. As is now apparent to those skilled in the art, many modifications and variations of the present disclosure are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the disclosure may be practiced otherwise than as specifically described.17Attorney Docket No. 065517.01022

Claims

CLAIMSWhat is claimed is:

1. A method of applying a vehicle seal to a surface of a component using an adhesive application device having a first applicator and a first spool and a seal application device having a second applicator and a second spool, said method comprising the steps of: winding a bonding material onto the first spool where the bonding material comprises a thermoplastic rubber-based pressure sensitive adhesive; winding a vehicle seal onto the second spool where the vehicle seal includes a bonding surface; softening the bonding material through the first applicator while simultaneously unwinding the bonding material from the first spool; applying the softened bonding material onto the surface of the component in a desired pattern; and applying the bonding surface of the vehicle seal onto the bonding material in the desired pattern while simultaneously unwinding the vehicle seal from the second spool.

2. The method of claim 1, wherein the desired pattern is a closed loop and the vehicle seal is an endless seal, and wherein said step of applying the bonding surface of the vehicle seal onto the bonding material is further defined as applying the bonding surface of the vehicle seal onto the bonding material in a continuous manner about the closed loop between a starting end and a terminal end of the vehicle seal.

3. The method of claim 1, wherein the desired pattern is a closed loop and the vehicle seal is an endless seal, and wherein said step of applying the bonding surface of the vehicle seal onto the bonding material is further defined as applying the bonding surface of the vehicle seal onto the bonding material about the closed loop such that a starting end of18Attorney Docket No. 065517.01022the vehicle seal is adjacent a terminal end of the vehicle seal with no gap between the starting end and the terminal end of the vehicle seal.

4. The method of any one preceding claim further comprising the step of warming the bonding material to a first temperature during said step of softening the bonding material, with the first temperature greater than or equal to a softening temperature of the bonding material.

5. The method of claim 4, wherein said step of applying the bonding surface of the vehicle seal onto the bonding material occurs after the bonding material has cooled to a second temperature below the softening temperature of the bonding material.

6. The method of claim 4, wherein said step of applying the bonding surface of the vehicle seal onto the bonding material occurs prior to the bonding material cooling to a second temperature below the softening temperature of the bonding material.

7. The method of any one preceding claim, wherein said step of winding a bonding material onto the first spool where the bonding material comprises a thermoplastic rubber-based pressure sensitive adhesive is further defined as winding a bonding material without a liner onto the first spool where the bonding material comprises a thermoplastic rubber-based pressure sensitive adhesive.

8. The method of any one preceding claim further comprising said step of extruding the vehicle seal having the bonding surface, and wherein said step of winding the vehicle seal onto the second spool is further defined as winding the extruded vehicle seal onto the second spool in a continuous manner.

9. The method of any one preceding claim, wherein the desired pattern defines one or more comers, and wherein said step of applying the softened bonding material onto the surface of the component in a desired pattern is further defined as applying the softened19Attorney Docket No. 065517.01022bonding material onto the surface of the component in a desired pattern through the one or more corners in a continuous manner.

10. The method of claim 9, wherein said step of applying the bonding surface of the vehicle seal onto the bonding material is further defined as applying the bonding surface of the vehicle seal onto the bonding material in the desired pattern in a continuous manner including around the one or more corners while simultaneously unwinding the vehicle seal from the second spool.

11. The method of any one preceding claim, wherein the component is further defined as a first component and further including a second component, and wherein the method further comprises the step of positioning the second component relative to the vehicle seal such that a force is applied by the second component transverse to a length of the vehicle seal to retain the vehicle seal on the bonding material.

12. The method of claim 11, wherein the step of positioning the second component relative to the vehicle seal is further defined as positioning the second component relative to the vehicle seal such that a portion of the vehicle seal and the bonding material are disposed between the first component and the second component.

13. The method of claim 12, wherein the step of positioning the second component relative to the vehicle seal is further defined as engaging the second component with a portion of the vehicle seal.

14. The method of claim 12, wherein the vehicle seal includes a bulb and a flange extending from the bulb with the flange and the bulb defining a gap therebetween, and wherein the step of positioning the second component relative to the vehicle seal is further defined as positioning the second component within the gap such that the flange and the bonding material are disposed between the first component and the second component.20Attorney Docket No. 065517.0102215. The method of claim 12, wherein the vehicle seal includes a bulb and a flange extending from the bulb with the flange and the bulb defining a gap therebetween, and wherein the method further comprises the step of positioning the first component and the bonding material within the gap such that the flange and the bonding material are disposed between the first and second components.

16. The method of any one preceding claim, wherein the adhesive application device includes a first robotic arm, and wherein the first robotic arm moves the first applicator relative to the outer surface of the component in an x-direction and / or in a y- direction corresponding to the desired pattern during said step of applying the softened bonding material onto the surface of the component in a desired pattern.

17. The method of any one preceding claim, wherein the seal application device includes a second robotic arm, and wherein the second robotic arm moves the second applicator relative to the outer surface of the component in an x-direction and / or in a y- direction corresponding to the desired pattern during said step of applying the bonding surface of the vehicle seal onto the bonding material in the desired pattern while simultaneously unwinding the vehicle seal from the second spool.21Attorney Docket No. 065517.0102218. A system for applying a vehicle seal to a surface of a component, said system comprising: an adhesive application device having a first applicator and a first spool with a bonding material wound onto the first spool where the bonding material comprises a thermoplastic rubber-based pressure sensitive adhesive; and a seal application device having a second applicator and a second spool with a vehicle seal wound onto the second spool where the vehicle seal includes a bonding surface; wherein the bonding material is extruded through the first applicator to soften the bonding material while simultaneously unwinding the bonding material from the first spool; wherein the softened bonding material is applied onto the surface of the component in a desired pattern; and wherein the bonding surface of the vehicle seal is applied onto the bonding material in the desired pattern while simultaneously unwinding the vehicle seal from the second spool.

19. The system of claim 18, wherein the bonding material comprises a viscoelastic acrylic adhesive having an acrylic foam core.

20. The system of claims 18 or 1 , wherein the bonding material is provided on the first spool without a liner.

21. The system of any one of claims 18 to 20, wherein the adhesive application device is configured to warm the bonding material to a first temperature as the bonding material is extruded through the first applicator with the first temperature greater than or equal to a softening temperature of the bonding material.22Attorney Docket No. 065517.0102222. The system of claim 21 , wherein the seal application device is configured to apply the bonding surface of the vehicle seal onto the bonding material in the desired pattern while simultaneously unwinding the bonding material from the second spool after the bonding material has cooled to a second temperature less than the softening temperature of the bonding material.

23. The system of claim 21 , wherein the seal application device is configured to apply the bonding surface of the vehicle seal onto the bonding material in the desired pattern while simultaneously unwinding the bonding material from the second spool prior to the bonding material cooling to a second temperature less than the softening temperature of the bonding material.

24. The system of claim 18, wherein the component is further defined as a first component and further including a second component spaced from the first component, and wherein the second component is positioned relative to the vehicle seal such that a force is applied by the second component transverse to a length of the vehicle seal to retain the vehicle seal on the bonding material.

25. The system of claim 24, wherein the second component is positioned relative to the vehicle seal such that a portion of the vehicle seal and the bonding material are disposed between the first component and the second component.

26. The system of claim 25, wherein the second component engages a portion of the vehicle seal.

27. The system of claim 25, wherein the vehicle seal includes a bulb and a flange extending from the bulb with the flange and the bulb defining a gap therebetween, and wherein the second component is positioned within the gap.23Attorney Docket No. 065517.0102228. The system of claim 25, wherein the vehicle seal includes a bulb and a flange extending from the bulb with the flange and the bulb defining a gap therebetween, and wherein the first component and the bonding material are positioned within the gap.

29. The system of any one of claims 18 to 28, wherein the adhesive application device comprises a first robotic device having a first robotic arm with the first applicator mounted to the first robotic arm.

30. The system of any one of claims 18 to 28, wherein the seal application device comprises a second robotic device having a second robotic arm with the second applicator mounted to the second robotic arm.24Attorney Docket No. 065517.01022

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