U.S. patent application number 11/037029 was filed with the patent office on 2005-06-09 for window assembly for a vehicle.
This patent application is currently assigned to Donnelly Corporation, a Michigan corporation. Invention is credited to Repp, R. Scott, Stallman, Pamela M..
Application Number | 20050121942 11/037029 |
Document ID | / |
Family ID | 22441056 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050121942 |
Kind Code |
A1 |
Repp, R. Scott ; et
al. |
June 9, 2005 |
Window assembly for a vehicle
Abstract
A window assembly for use in a vehicle comprises a glass panel
having inner and outer sides. A latch element having a latch
attachment portion and at least one hinge element having a hinge
attachment portion are joined via a substantially cured adhesive at
the inner side of said glass panel such that there is no exposure
of the latch element and the hinge element on the outer side of the
glass panel. The substantially cured adhesive is selected from the
group consisting of a moisture-activated adhesive, a
thermally-activated adhesive, a chemically-activated adhesive, an
aerobically-cured adhesive, an anaerobically-cured adhesive, and a
radiation-cured adhesive. The window assembly is adapted for
mounting on the vehicle such that when fitted within a generally
vertical window opening of the vehicle, the glass panel will be
generally vertically mounted, and the window assembly preferably
comprises one of a side window, rear window, and lift gate window
of the vehicle.
Inventors: |
Repp, R. Scott; (Holland,
MI) ; Stallman, Pamela M.; (Lawton, MI) |
Correspondence
Address: |
VAN DYKE, GARDNER, LINN AND BURKHART, LLP
2851 CHARLEVOIX DRIVE, S.E.
P.O. BOX 888695
GRAND RAPIDS
MI
49588-8695
US
|
Assignee: |
Donnelly Corporation, a Michigan
corporation
Holland
MI
|
Family ID: |
22441056 |
Appl. No.: |
11/037029 |
Filed: |
January 18, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11037029 |
Jan 18, 2005 |
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09957285 |
Sep 20, 2001 |
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6871450 |
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09957285 |
Sep 20, 2001 |
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09628455 |
Jul 31, 2000 |
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6298606 |
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09628455 |
Jul 31, 2000 |
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09351502 |
Jul 12, 1999 |
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6128860 |
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09351502 |
Jul 12, 1999 |
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08998124 |
Dec 24, 1997 |
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5966874 |
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08998124 |
Dec 24, 1997 |
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08659269 |
Jun 6, 1996 |
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5704173 |
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08659269 |
Jun 6, 1996 |
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08129671 |
Sep 30, 1993 |
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5551197 |
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Current U.S.
Class: |
296/146.15 |
Current CPC
Class: |
B60J 1/14 20130101 |
Class at
Publication: |
296/146.15 |
International
Class: |
B60J 001/10 |
Claims
1. (canceled)
2. A window assembly for use in a vehicle, said window assembly
comprising: a glass panel having inner~and outer sides; a latch
element having a latch attachment portion; at least one hinge
element having a hinge attachment portion; an adhesive joint
joining said latch attachment portion of said latch element at a
portion of said inner side of said glass panel such that there is
no exposure of said latch element on said outer side of said glass
panel; an adhesive joint joining said hinge attachment portion of
said hinge element at a portion of said inner side of said glass
panel such that there is no exposure of said hinge element on said
outer side of said glass panel; wherein said adhesive joints
comprise a substantially cured adhesive selected from the group
consisting of a moisture-activated adhesive, a thermally-activated
adhesive, a chemically-activated adhesive, an aerobically-cured
adhesive, an anaerobically-cured adhesive, and a radiation-cured
adhesive; wherein said window assembly is adapted for mounting on
the vehicle such that when fitted within a generally vertical
window opening of the vehicle, said glass panel will be generally
vertically mounted; and wherein said window assembly comprises one
of a side window, a rear window, and a lift gate window of the
vehicle.
3. The window assembly of claim 2 wherein a substantially opaque
coating is disposed at said portions of said inner side of said
glass panel.
4. The window assembly of claim 3 including an adhesion promoting
compound between said substantially opaque coating and at least one
of said latch element and said hinge element.
5. The window assembly of claim 2 wherein said adhesive comprises a
urethane adhesive.
6. The window assembly of claim 5 wherein said urethane adhesive
comprises a moisture-activated urethane adhesive.
7. The window assembly of claim 2 wherein said adhesive comprises a
silicone adhesive.
8. The window assembly of claim 7 wherein said silicone adhesive
comprises a moisture-activated silicone adhesive.
9. The window assembly of claim 7 wherein said silicone adhesive
comprises a thermally-activated silicone adhesive.
10. The window assembly of claim 2 wherein said joint joining said
latch element to said inner side of said panel withstands a pull of
about 150 pounds.
11. The window assembly of claim 2 wherein said adhesive comprises
a nitrile-phenolic adhesive.
12. The window assembly of claim 11 wherein said nitrile-phenolic
adhesive comprises a thermally-activated nitrile-phenolic
adhesive.
13. The window assembly of claim 2 wherein at least one of said
latch element and said hinge element has at least one projection
for spacing from said glass panel.
14. The window assembly of claim 2 wherein said joint joining said
hinge element to said inner side of said panel withstands a pull of
about 150 pounds.
15. The window assembly of claim 2 wherein said adhesive comprises
an acrylate adhesive.
16. The window assembly of claim 15 wherein said acrylate adhesive
comprises a chemically-activated acrylate adhesive.
17. The window assembly of claim 2 wherein said adhesive comprises
an epoxy adhesive.
18. The window assembly of claim 17 wherein said epoxy adhesive
comprises a thermally-activated epoxy adhesive.
19. The window assembly of claim 2 wherein said adhesive comprises
a chemically-activated adhesive.
20. The window assembly of claim 2 wherein said adhesive comprises
a thermally-activated adhesive.
21. The window assembly of claim 2 wherein said adhesive comprises
a moisture-activated adhesive.
22. The window assembly of claim 2 wherein said latch element is
formed from one of a metal material, a plastic material, and
composite material.
23. The window assembly of claim 2 wherein said vehicle comprises
one of a van, a station wagon, a utility vehicle, and a truck.
24. A window assembly for use in a vehicle, said window assembly
comprising: a glass panel having inner and outer sides; a latch
element having a latch attachment portion; at least one hinge
element having a hinge attachment portion; an adhesive joint
joining said latch attachment portion of said latch element at a
portion of said inner side of said glass panel such that there is
no exposure of said latch element on said outer side of said glass
panel; an adhesive joint joining said hinge attachment portion of
said hinge element at a portion of said inner side of said glass
panel such that there is no exposure of said hinge element on said
outer side of said glass panel; wherein said adhesive joints
comprise a substantially cured adhesive selected from the group
consisting of a) a urethane adhesive, b) a silicone adhesive, c) an
epoxy adhesive, d) an acrylate adhesive, and e) a nitrile-phenolic
adhesive; wherein said window assembly is adapted for mounting on
the vehicle such that when fitted within a generally vertical
window opening of the vehicle, said glass panel will be generally
vertically mounted; and wherein said window assembly comprises one
of a side window, a rear window, and a lift gate window of the
vehicle.
25. The window assembly of claim 24 wherein a substantially opaque
coating is disposed at said portions of said inner side of said
glass panel.
26. The window assembly of claim 25 including an adhesion promoting
compound between said substantially opaque coating and at least one
of said latch element and said hinge element.
27. The window assembly of claim 24 wherein said adhesive comprises
a urethane adhesive.
28. The window assembly of claim 27 wherein said urethane adhesive
comprises a moisture-activated urethane adhesive.
29. The window assembly of claim 24 wherein said adhesive comprises
a silicone adhesive.
30. The window assembly of claim 29 wherein said silicone adhesive
comprises a moisture-activated silicone adhesive.
31. The window assembly of claim 29 wherein said silicone adhesive
comprises a thermally-activated silicone adhesive.
32. The window assembly of claim 24 wherein said joint joining said
latch element to said inner side of said panel withstands a pull of
about 150 pounds.
33. The window assembly of claim 24 wherein said adhesive comprises
a nitrile-phenolic adhesive.
34. The window assembly of claim 33 wherein said nitrile-phenolic
adhesive comprises a thermally-activated nitrile-phenolic
adhesive.
35. The window assembly of claim 24 wherein at least one of said
latch element and said hinge element has at least one projection
for spacing from said glass panel.
36. The window assembly of claim 24 wherein said joint joining said
hinge element to said inner side of said panel withstands a pull of
about 150 pounds.
37. The window assembly of claim 24 wherein said adhesive comprises
an acrylate adhesive.
38. The window assembly of claim 37 wherein said acrylate adhesive
comprises a chemically-activated acrylate adhesive.
39. The window assembly of claim 24 wherein said adhesive comprises
an epoxy adhesive.
40. The window assembly of claim 39 wherein said epoxy adhesive
comprises a thermally-activated epoxy adhesive.
41. The window assembly of claim 24 wherein said adhesive comprises
a chemically-activated adhesive.
42. The window assembly of claim 24 wherein said adhesive comprises
a thermally-activated adhesive.
43. The window assembly of claim 24 wherein said adhesive comprises
a moisture-activated adhesive.
44. The window assembly of claim 24 wherein said latch element is
formed from one of a metal material, a plastic material, and
composite material.
45. The window assembly of claim 24 wherein said vehicle comprises
one of a van, a station wagon, a utility vehicle, and a truck.
46. A window assembly for use in a vehicle, said window assembly
comprising: a glass panel having inner and outer sides; a latch
element having a latch attachment portion; at least one hinge
element having a hinge attachment portion; an adhesive joint
joining said latch attachment portion of said latch element at a
portion of said inner side of said glass panel such that there is
no exposure of said latch element on said outer side of said glass
panel; an adhesive joint joining said hinge attachment portion of
said hinge element at a portion of said inner side of said glass
panel such that there is no exposure of said hinge element on said
outer side of said glass panel; wherein said adhesive joints
comprise a substantially cured adhesive selected from the group
consisting of a moisture-activated adhesive, a thermally-activated
adhesive, a chemically-activated adhesive, an aerobically-cured
adhesive, an anaerobically-cured adhesive, and a radiation-cured
adhesive; a substantially opaque coating disposed at said portions
of said inner side of said glass panel; an adhesion promoting
compound disposed between said substantially opaque coating and at
least one of said latch element and said hinge element; wherein
said window assembly is adapted for mounting on the vehicle such
that when fitted within a generally vertical window opening of the
vehicle, said glass panel will be generally vertically mounted; and
wherein said window assembly comprises one of a side window, a rear
window, and a lift gate window of the vehicle.
47. The window assembly of claim 46 wherein said substantially
opaque coating comprises a frit coating.
48. The window assembly of claim 46 wherein said adhesive comprises
a urethane adhesive.
49. The window assembly of claim 48 wherein said urethane adhesive
comprises a moisture-activated urethane adhesive.
50. The window assembly of claim 46 wherein said adhesion promoting
compound comprises one of a silicon compound, a titanium compound
and zirconium compound.
51. The window assembly of claim 46 wherein said adhesive comprises
a silicone adhesive.
52. The window assembly of claim 51 wherein said silicone adhesive
comprises a moisture-activated silicone adhesive.
53. The window assembly of claim 51 wherein said silicone adhesive
comprises a thermally-activated silicone adhesive.
54. The window assembly of claim 46 wherein said joint joining said
latch element to said inner side of said panel withstands a pull of
about 150 pounds.
55. The window assembly of claim 46 wherein said adhesive comprises
a nitrile-phenolic adhesive.
56. The window assembly of claim 55 wherein said nitrile-phenolic
adhesive comprises a thermally-activated nitrile-phenolic
adhesive.
57. The window assembly of claim 46 wherein at least one of said
latch element and said hinge element has at least one projection
for spacing from said glass panel.
58. The window assembly of claim 46 wherein said joint joining said
hinge element to said inner side of said panel withstands a pull of
about 150 pounds.
59. The window assembly of claim 46 wherein said adhesive comprises
an acrylate adhesive.
60. The window assembly of claim 59 wherein said acrylate adhesive
comprises a chemically-activated acrylate adhesive.
61. The window assembly of claim 46 wherein said adhesive comprises
an epoxy adhesive.
62. The window assembly of claim 61 wherein said epoxy adhesive
comprises a thermally-activated epoxy adhesive.
63. The window assembly of claim 46 wherein said adhesive comprises
a chemically-activated adhesive.
64. The window assembly of claim 46 wherein said adhesive comprises
a thermally-activated adhesive.
65. The window assembly of claim 46 wherein said adhesive comprises
a moisture-activated adhesive.
66. The window assembly of claim 46 wherein said latch element is
formed from one of a metal material, a plastic material, and
composite material.
67. The window assembly of claim 46 wherein said vehicle comprises
one of a van, a station wagon, a utility vehicle, and a truck.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to flush-mounted window
assemblies for vehicles and more particularly, to flush-mounted
vehicular window assemblies which articulate about a hinge attached
to one side of the window in a manner to achieve long-term
reliability.
BACKGROUND OF THE INVENTION
[0002] In an effort to make automobiles more fuel-efficient,
automobile exterior designs are becoming more streamlined. To
achieve this goal, automobile manufacturers are requiring
flush-mounted panel and window assemblies. The goal is to locate
the panel or window within the vehicle such that the peripheral
edge of the panel or window assembly is recessed and the outer
surface of the panel is generally flush with any adjoining body
panels. In the case of fixed panels, a conventional technique
includes placing or running a bead of adhesive material around the
entire inside peripheral edge of the panel and bonding it in the
vehicle opening. While satisfactory for stationary windows, this
method creates problems with movable windows, however, particularly
those which articulate about a hinge.
[0003] Conventional articulated or hinged windows are fixed to the
vehicle by a mounting assembly which is fastened by a stud passing
through a hole drilled in the panel. A low profile nut is then
threaded onto the stud extending through the panel to retain the
panel thereon. A major disadvantage is that a significant number of
glass panels are broken as a result of drilling the holes through
the panel. The panels are also broken (during or after mounting of
the mounting hardware. To avoid the breakage of the glass panel,
sophisticated techniques have been adopted to drill the holes, and
the mounting hardware has been adapted to reduce breakage. As a
result, the price of such panel assemblies is unnecessarily high.
Moreover, the resulting panel is not truly flush since the mounting
hardware has a positive relief with respect to the panel exterior
surface.
[0004] Another attempt to reduce the exterior profile of
articulated window assemblies is disclosed in U.S. Pat. No.
4,396,221 which employs a channel extending around the edge of the
window pane, a flexible resilient portion allowing pivotal movement
of the window pane, and one of several types of fasteners. Such
fasteners include a clip with a detent received in the seal and
securing the hinge and thus the assembly to a pinch weld
flange.
[0005] Another embodiment of the hinged window assembly just
described includes a substantially rectilinear hinge member which
includes a retaining end bonded to the exterior or front surface of
the window panel by an adhesive and an opposing retaining end
having an aperture which receives a metal screw extending into the
vehicle body. Seated on the pinch-weld flange is a sealing weather
strip which forms a closed bulbous portion engaging both the inside
surface of the pane as well as a shoulder of the recess leading to
the pinch weld flange on the exterior sheet metal body portion. To
conceal the fastener for the hinge, a metal covering extending from
the vehicle roof or another portion of the vehicle may extend over
the fastener and a substantial portion of the hinge.
[0006] A disadvantage associated with each of the above hinged
windows is that the hinge member is fixed to the exterior surface
of the panel. In addition, in the last embodiment described above,
the fastener securing the assembly to the vehicle is exposed, or
must include a special cover member. Accordingly, the exterior
profile of these window assemblies do not result in a truly
flush-mounted, articulated window assembly.
[0007] Although known in the art to adhesively bond metal to glass
for a variety of purposes such as stud attachments, small hinge
plates, etc., known hinge adhesives and hinge designs are
inadequate to meet load requirements and long-term environmental
resilience required for flush-mounted, hinged window assemblies.
Hinge mounting of large size, flush-mounted panels in the nature of
van windows is a demanding application of adhesive technology. The
higher weight of such a window transmits more severe vibration
requiring greater strength and greater long-term environmental
resilience and durability than is available with such prior known
bonds. Styling and design limitations restrict the number of hinges
and the size of the bond areas.
[0008] Accordingly, there is now a need for large panels such as
van or tailgate windows having a flush mounted hinge, and an
improved bond between a hinge member and the single panel surface
to which it is attached to support the panel.
SUMMARY OF THE INVENTION
[0009] The present invention includes a unique articulated window
assembly especially for vehicles, and a method for manufacturing
the panel assembly.
[0010] The panel assembly of this invention is especially useful as
a flush-mounted vehicle window assembly, and includes, in
combination, a panel having inner and outer surfaces which
terminate in a peripheral edge and give the panel a predetermined
geometric shape. At least one mounting member is secured to the
inner surface of the panel and spaced from the peripheral edge. An
adhesive is used to bond a flange of the mounting member to the
inner surface of the panel. The resulting bond between the mounting
member flange and the panel is sufficiently strong such that when a
load sufficient to induce failure is imposed between the mounting
member and the panel, failure of the panel assembly results other
than in the adhesion of the adhesive to the mounting member or
panel. More specifically, failure may occur as cohesive failure of
the adhesive, mechanical failure of the mounting member adjacent
the adhesive, or mechanical failure of the panel adjacent the
adhesive. The bond is preferably strong enough to withstand a
failure load of at least 150 pounds.
[0011] One embodiment of the invention includes an articulated
window assembly for use in a vehicle wherein the window assembly is
mounted in the window opening from the inner surface with the
opposite surface generally flush with the exterior surface of the
vehicle. The articulated window assembly includes, in combination,
a transparent sheet having inner and outer surfaces terminating in
a peripheral edge and defining a shape to fit within the window
opening. At least one window-mounting member is bonded to the inner
surface of the sheet at a position spaced inwardly from the
peripheral edge and fixing the sheet in the window opening. The
mounting member may include a plurality of projections extending
therefrom for spacing the mounting member from the inner surface of
the sheet by a predetermined distance. One or more adhesives are
provided between the inner surface of the sheet and the mounting
member for bonding the sheet and mounting member together in such a
manner that when tested under a straight pull test of more than 150
pounds applied at a rate greater than 25 millimeters per minute,
failure will occur generally in the sheet, the mounting member or
the cohesiveness of the adhesive will fail, but the adhesion of the
adhesive to the sheet or mounting member will not fail. Such
strength is also maintained after soaking in 80.degree. C. water
for at least 100 hours.
[0012] Another embodiment of the invention includes a hinged window
panel having a shape to fit within the window opening of a vehicle
with an outer surface of the peripheral edge aligned generally
flush with an outer surface of the window opening. At least one
hinge assembly includes a flange portion which is located on the
inner surface of the panel inwardly from the peripheral edge and a
hinged portion for engaging the window opening. At least one
latch-mounting member is provided having a base portion located on
the inner surface of the panel inwardly from the peripheral edge
and spaced from the hinge assembly. The latch-mounting member also
includes an end portion to receive a latch interconnected to the
inside of the window opening. A first adhesive is optionally
provided having a quick set-up time, for temporarily fixturing the
hinge assembly and the latch-mounting member to the inner surface
of the panel. A second adhesive is then provided for permanently
bonding the hinge assembly and latch member to the inner surface of
the panel and has a set-up or cure time greater than the first
adhesive.
[0013] According to additional aspects of the invention, the panel
or transparent sheet may further include an opaque coating such as
a ceramic frit between the inner surface of the panel and the
adhesive bonding the mounting member, hinge or latch member, to the
panel. An adhesion-promoting compound may also be applied to the
opaque coating, mounting member, hinge or latch-mounting member, to
enhance the bond with the adhesive.
[0014] The panel assemblies of this invention have advantages over
the prior art in that the mounting members do not need to be fixed
by holes drilled through the panel yet provide a strong and
resilient bond between the panel and the vehicle. Another advantage
is that the mounting members no longer wrap around the exterior
edge of the window panel or are exposed on the exterior of the
window panel. Moreover, the panel assembly of this invention may be
manufactured rapidly without complex machines, and is highly
adapted for support of larger sized, heavier windows in vehicles in
which significant vibration is encountered. Because the mounting
members are fixed to the panel by an adhesive, fewer panels are
broken during the manufacturing process. A still further advantage
of the panel assembly of this invention is that the mounting
members do not extend through and protrude from the panel, but are
concealed on the inner surface of the panel which results in a
flush, more streamlined and aesthetically pleasing panel assembly
appearance.
[0015] The above advantages, purposes and other features of the
invention will become apparent from a study of the following
detailed description taken in conjunction with the appended drawing
figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0016] FIG. 1 is a fragmentary perspective view of the articulated
panel assembly of this invention mounted as a side window in a
vehicle;
[0017] FIG. 2 is a side elevational view of an exterior surface of
the articulated panel assembly of FIG. 1;
[0018] FIG. 3 is a side elevational view of the opposite, inner
surface of the articulated panel assembly shown in FIG. 2;
[0019] FIG. 4 is a plan view of one embodiment of a hinge mounted
on the panel of FIGS. 1-3;
[0020] FIG. 5 is a fragmentary sectional view of the panel and
hinge taken along line V-V in FIG. 4;
[0021] FIG. 6 is a fragmentary sectional view of the panel and
hinge taken along line VI-VI in FIG. 4;
[0022] FIG. 7 is a fragmentary plan view of one embodiment of a
mounting stud for use in association with a latching mechanism, the
stud being mounted on the panel assembly of FIGS. 1-3;
[0023] FIG. 8 is a fragmentary sectional view of the panel assembly
and mounting stud taken along line VIII-VIII in FIG. 7;
[0024] FIG. 8A is a fragmentary sectional view of the panel
assembly and mounting stud taken along line VIIIA-VIIIA in FIG.
8;
[0025] FIG. 9 is a fragmentary sectional view of the panel assembly
in a closed position on a vehicle and taken along line IX-IX in
FIG. 1;
[0026] FIG. 10 is a fragmentary sectional view of the panel
assembly on a vehicle and taken along line X-X in FIG. 1;
[0027] FIG. 11 is a fragmentary sectional view of the panel
assembly on a vehicle and taken along line XI-XI in FIG. 1;
[0028] FIG. 12 is a fragmentary sectional view of the panel
assembly on a vehicle and taken along line XII-XII in FIG. 1;
[0029] FIG. 13 is a fragmentary plan view of another embodiment of
a hinge adapted for mounting on the panel of FIGS. 1-3;
[0030] FIG. 14 is a fragmentary sectional view of the panel and
hinge taken along line XIV-XIV in FIG. 13; and
[0031] FIG. 15 is a fragmentary sectional view of the hinge of
FIGS. 13 and 14 taken along line XV-XV in FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Although this invention relates to flush-mounted articulated
window panels for vehicles, the advantages of this invention are
best realized in large flush-mounted articulated window panels such
as used in side windows for vans, rear lift gate windows for vans,
station wagons, utility vehicles, and trucks, and other vehicles
such as aeronautical, nautical, rail, and other forms of
transportation, which exerts substantial loads on the bonds between
the mounting hardware and the window panel such window panels have
surface areas typically greater than 250 square inches.
[0033] Referring now to the drawings in greater detail, panel
assembly 12 of the present invention is disposed on a vehicle 10
within a window opening 14 formed in the vehicle exterior 16. Panel
or window assembly 12 is adapted to articulate or pivot about a
pair of mounting members 30 (FIGS. 3-6) positioned proximate
peripheral edge 18 of inside surface 22. Panel assembly 12 is
opened or closed about mounting members 30 by a second mounting
member 32 (FIGS. 2-3) interconnecting the vehicle 10 to a second
portion of panel assembly 12 distant and spaced from mounting
members 30. Although panel assembly 12 is shown pivoting about an
axis proximate the leading peripheral edge 18, it is contemplated
that this invention may also be used to articulate panels such as a
rear window or tailgate window about a horizontal axis as well.
[0034] In one embodiment, panel assembly 12 includes a panel or
sheet 24 having outer and inner surfaces 20, 22, respectively.
Panel 24 is preferably transparent glass which may be tempered,
laminated, or otherwise strengthened using conventional techniques
and principles. Panel 24 may be curved, bent or generally planar,
having two substantially parallel sides, surfaces, or faces 20, 22
terminating in a peripheral edge 18 forming a panel having a
predetermined geometric shape. Although transparent glass is
preferred, other sheet-like panel materials may also be used, such
as opaque or coated glass, transparent coated or opaque plastic
materials, or multi-composite laminates, such as transparent glass
and plastic.
[0035] Optionally and preferably, deposited on and bonded to
surface 22 of panel 24 is an opaque, and preferably black frit
layer 26, and most preferably, a ceramic frit layer or coating
covering and concealing a region of surface 22 from peripheral edge
18 inward. Alternatively, frit layer 26 may cover all or
substantially all of surface 22. Usually, however, frit layer 26
conceals a continuous peripheral strip of surface 22 near edge 18,
such as two inches in from edge 18, as shown in FIGS. 2 and 3.
[0036] Glass panel 24, which is initially in an untempered
condition after cutting and sizing to its desired shape, can be
painted by screen coating or other techniques, with a coating of
dark ceramic paint on its inner surface 22. Thereafter, glass panel
24 is heated and bent to the desired contour with a bending furnace
or other bending apparatus, followed by tempering to strengthen the
glass. Such heating, bending and tempering operations cause the
ceramic paint 26 to become fused to surface 22. Thus, although
starting as a layer of paint containing ceramic particles and
pigment, coating 26 ends up after bending and tempering, as a thin
frit layer of ceramic material, which, in actuality, is fused to
surface 22 of glass panel 24. Since ceramic frit coating 26
includes a pigment of a desired color, preferably a dark color such
as black or the like, the layer results in a permanent, second or
inside surface coloration of glass panel 24. When viewed from the
opposite or outer side 20, the transparent thickness of panel 24,
backed up by the colored ceramic frit layer 26, provides an
appearance of depth and richness which blends well with the
surrounding painted or glass areas on a vehicle.
[0037] One ceramic paint used to form the opaque black ceramic frit
coating 26, described above, is manufactured by the Drakenfeld
Pigments Division of Ciba-Geigy Corporation located in Washington,
Pa. Such paint includes small ceramic particles and a suitable
metal oxide pigment suspended in oil of a type conventionally known
in the art. The resulting frit layer is opaque and normally black
in color. This ceramic paint is preferably screen-coated on a
predetermined portion of inner surface 20 of panel 24 using a
200-mesh screen. Ceramic particles in layer 26 are melted and fused
to one another, are permanently bonded and fused to the inner glass
surface 22, and form the equivalent of the glass itself in terms of
strength and adherence.
[0038] Fixed to ceramic frit layer 26 and spaced inwardly from
peripheral edge 18 toward the center of the panel are at least one,
and preferably no more than two, mounting members 30, and at least
one member 32 which cooperate to retain and articulate panel
assembly 24 within window opening 14. Each mounting member 30, 32,
is bonded at least 0.125 inch inboard of peripheral edge 18 to
panel inner surface 22 to retain panel 24 within window opening 14
without the need to extend a fastener through the sheet-like panel
24 or encapsulate the peripheral edge 18 of panel 24 with a
resinous gasket extending around the panel edge on both inner and
outer surfaces or the like. Described in greater detail below, the
bond between mounting members 30, 32 and glass panel 24 and/or frit
layer 26 is sufficient to withstand loads greater than 150 pounds,
preferably greater than 250 pounds, and most preferably about 300
pounds, even after environmental exposure. The resulting bond is
such that if failure occurs under these loads, the failure mode is
other than in the adhesive bond interface between mounting members
30, 32 and panel 24. That is to say, if a failure occurs in the
bond between mounting members 30, 32 and panel 24 under a load, the
failure mode will be a mechanical failure of the substrate
(mounting member or panel) or in the cohesion of the adhesive
itself. For the purposes of this description, the adhesive bond or
adhesion of the adhesive with the mounting member or panel is the
ability of the adhesive to adhere to the substrate. Cohesion is the
ability of the adhesive to bond with itself.
[0039] In one embodiment (FIGS. 4-6), each mounting member 30 is a
0.1 to 10.0 millimeter (mm) thick, and preferably 0.5 to 1.0 mm
thick, 1050 spring steel hinge having an elongate flange portion 34
with one edge 36 defining an adjoining tab 38. Tab 38 is offset
from the plane of flange 34 by leg 37. Tab 38 is thus bent in an
S-shaped form with respect to flange 34 although the free end
portion tab 38 is generally parallel to flange 34. The bends
between tab 38 and flange 34, and particularly leg 37, provide a
spring-like hinge, the operation of which will become readily
apparent below. Hinge flange 34 may also be prestressed or bent to
conform to the surface of panel 24, especially if the panel is
curved. In this regard, it is desirable to have a convex curvature
to the surface of hinge flange 34 that is adhesively bonded to
panel surface 24. This results in not only a more uniform adhesive
bond, but also evenly distributes any load along the bonding
surface and economizes the amount of adhesive used. Extending
through tab 38 and away from panel 24 is a stud 52, having a head
53 bonded with or welded to tab 38. The opposite end of stud 52 is
to be fastened to the vehicle as explained below.
[0040] Optionally, formed in flange portion 34, and extending
therethrough, are a plurality of holes 40 generally aligned along
the longitudinal axis of the flange. The size of each hole may
range from 0.1 to 10 mm or more, but is preferably about 3.0
millimeters. In the preferred embodiment, holes 40 are spaced
equidistantly from each other with the center points between the
holes being approximately eight and one-half millimeters apart. The
size and spacing of holes 40 are designed to provide optimum access
of both air and moisture/humidity to permeate to an underlying
adhesive described in greater detail below. The perforations also
reduce the weight of each hinge, and provide a mechanical surface
to bond with the adhesive and aid in bonding the hinge to the
panel.
[0041] Flange portion 34 also contains embossments 42 adjacent
aligned holes 40 which extend from a lower surface 44 of flange 34
and serve to space flange 34 from the inner surface 22 of panel 24.
In a preferred embodiment, embossments 42 extend from flange 34 by
a distance on the order of 0.1 to 3.0 mm, and preferably 1.0 mm.
The actual distance may vary depending on the type of adhesive
used. However, this offset distance has been found to be quite
adequate for the variety of adhesives described below. Holes 40 and
embossments 42 may be easily formed in flange portion 34 by
stamping or punching during the formation of spring hinge 30.
[0042] For panel assemblies employing a single hinge 30, it is
preferred that the surface area of flange 34 bonded to panel 24 be
approximately between 4 square inches and 50 square inches, and
most preferably approximately 15 square inches. On a two-hinge
system, each hinge would preferably have a bonding area
approximately between 2 and 50 inches square, and most preferably
on the order of 4 square inches. The aspect ratio (ratio of length
to width) of each hinge, no matter whether a single hinge or dual
hinge system, is preferably greater than 1 but less than 1,000, and
most preferably approximately 8 to 10. Dimensions may vary
depending upon the specific application. However, the hinge design
is intended to provide the most bonding strength and structural
stability economically and concealing the hinge in the frit area on
the panel.
[0043] Although hinge 30 is described as being made from spring
steel, other materials may also be used such as cold rolled steel,
plastics, composite materials and other materials which are capable
of withstanding flexural or bending moments. These materials will
become apparent to one of ordinary skill in the art.
[0044] Referring to FIGS. 5 and 6, flange 34 of hinge 30 has its
lower surface 44 bonded to frit layer 26 by a first and second
adhesive 46 and 48, respectively. In a preferred embodiment,
adhesive 48 is a temporary fixturing adhesive such as a hot-melt
thermoplastic, which temporarily locates or fixtures hinge 30
against frit 26, while adhesive 46 cures and forms the permanent
primary bond. Adhesive 46 may be selected from a number of
adhesives classes including moisture-activated urethanes such as
described in U.S. Pat. No. 3,707,521 incorporated herein by
reference, moisture-activated silicones, moisture-curable activated
urethanes, chemically-activated adhesives, and thermally-activated
adhesives, such as shown in Table I below. Other adhesives, such as
aerobically-cured, anaerobically-cured, and radiation-cured
adhesives can also be used. When cured, the bond-line thickness is
in the range of 1 micron to 10 mill, preferably 5 microns to 5 mm,
and most preferably 25 microns to 1 mm. For large area vehicle
windows where load integrity over a long surface life and through
extreme climatic conditions is critical, thermosetting adhesives
such as urethanes, silicones, acrylates, and epoxies are preferred
over thermoplastic adhesives such as polyvinylbutyral. For
moisture-activated adhesives, it is preferable that the assemblies
be exposed to a high humidity atmosphere after initial bonding is
achieved in order to promote rapid, complete cure of the adhesive.
In this regard, it is preferable that the assemblies be exposed to
a relative humidity in excess of 40 percent R.H. and preferably, in
excess of 75 percent R.H. for a time period ranging from about 30
minutes to approximately 24 hours, or longer, and at a temperature
range from about 60.degree. F. to about 250.degree. F., preferably
about 75.degree. F. to about 110.degree. F. Chemically-activated
adhesives can be activated by means such as catalysts, curing
agents, and their equivalents as conventionally known in the
adhesive arts. Activation can be promoted by heat and/or by
radiation including ultraviolet radiation and microwave radiation.
Thermally-activated adhesives may be activated by a variety of
heating means including convective heating, infrared heating,
focused infrared heating, inductive or induction heating,
conductive heating, microwave heating and their equivalents such as
are described in co-pending U.S. patent application Ser. No.
897,764. Cure of the bond joint and the assemblies can be promoted
and achieved by use of ovens, high humidity chambers, conveyors,
heaters and by their combination.
1TABLE I Manufacturer Trade Name Type Essex Specialty BetaSeal .TM.
57302 Moisture-activated Chemicals.sup.1 urethane Morton
Yokohama.sup.2 WS70-FK Moisture-activated urethane Sika.sup.3
Sika-Flex .TM. 255-FC Moisture-activated urethane Dow Corning.sup.4
732 Moisture-activated silicone Dow Corning Q3-6611
Thermally-activated silicone Dow Corning X3-6265
Thermally-activated silicone 3M.sup.5 JetWeld .TM. TS-230
Moisture-curable hot melt urethane 3M Scotchweld AF-126-2
Thermally-activated modified epoxy 3M Scotchweld AF-163-2U
Thermally-activated modified epoxy Dymax.sup.6 625-BT
Chemically-activated acrylate Ciba Geigy.sup.7 R 382-3
Thermally-activated modified epoxy Ciba Geigy R 609
Thermally-activated modified epoxy Dexter Adhesives.sup.8 EA 9628
Thermally-activated modified epoxy B.F. Goodrich.sup.9 PL-760
Thermally-activated modified epoxy B.F. Goodrich PL-776
Thermally-activated modified epoxy B.F. Goodrich PL-633
Thermally-activated nitrile-phenolic .sup.1Essex Specialty
Products, Sayreville, New Jersey .sup.2Morton International,
Ridgewood Illinois .sup.3Sika, Southfield, Michigan .sup.4Dow
Corning, Midland, Michigan .sup.53M Corporation, St. Paul,
Minnesota .sup.6Dymax, Engineering Adhesives, Torrington,
Connecticut .sup.7Ciba Geigy, Anaheim, California .sup.8Dexter
Adhesive & Structural Materials of Pittsburgh, California
.sup.9B.F. Goodrich, Adhesives Systems Division, Akron, Ohio
[0045] It is further preferred that the selected adhesive come in a
single package so that no mixing of reactants need occur prior to
application. The one-package adhesives provide a much more
efficient method than prior adhesives requiring mixing of
reactants. It is further preferred that the adhesive have a
jelly-like consistency, preferably having a viscosity at 25.degree.
C. greater than 5 Poise, and most preferably greater than 100
Poise, or can also be a hot-melted adhesive, or in film form for
easy application. Adhesive 46 is preferably a urethane adhesive and
most preferably a moisture-activated adhesive urethane such as
Morton Yokohama WS70-FK, available from Morton International of
Ridgewood, Ill., although epoxies and activated adhesives may also
be used. Stand-offs or embossments 42 provide a space between hinge
flange 34 and the surface of frit layer 26 for adhesive 46. In
addition, holes 40 extending the length of hinge flange 34 allow
adhesive 46 to be extruded therethrough to provide a mechanical
coupling due to the extension of adhesive over the edges of the
holes 40, as well as to provide an avenue for the permeation of
moisture to complete the cure of the adhesive.
[0046] To improve and promote the bonding characteristics of
adhesive 46 glass inner surface 22 or frit layer 26, and/or the
lower surface 44 of hinge flange 34 may be coated with an
adhesion-promoting compound or primer 50. These adhesion-promoting
compounds generally include silanes such as available from Dow
Corning, or titanium or zirconium coupling agents such as available
from Kenrich Petrochemical, Inc., of Bayon, N.J., or equivalents,
which greatly enhance the bonding ability of the adhesive to the
substrate. If the primer 50 is applied to frit layer 26 or onto
glass surface 22, a preferred primer is designated Morton Yokohama
MS-90 available from Morton International in Ridgewood, Ill. If
primer 50 is applied to a metallic surface such as hinge flange 34,
a preferred primer is Morton Yokohama RC-50, also available from
Morton International. Although these two primers are preferred,
they are not the only primers available which may be equally if not
more suitable for the application. Although the adhesion-promoting
compound 50 may be applied to frit coating 26 and to lower surface
44 of flange 34, FIGS. 5 and 6 illustrate the primer compound only
on frit coating 26. Adhesive 46, combined with adhesion-promoting
compound or primer 50, provides a bond between frit coating 26 and
hinge 30, which exceeds standards established by many U.S.
automobile manufacturers for window panels. Bonding strengths will
vary depending upon the bonding surface area and the types of base
materials used. Based upon the materials described herein, the
majority of bonds withstood straight pull tests of more than 150
pounds applied at a rate of 25 millimeters per minute without a
failure of the cohesion or adhesion after environmental
exposure.
[0047] In a first embodiment of window panel assembly 12, two
hinges 30, such as described above, are bonded to frit coating 26
inwardly from peripheral edge 18 and spaced from each other so as
to provide generally balanced support for panel assembly 12. To
locate panel assembly 12 within window opening 14, a mounting stud
52 passing through hinge flange or tab 38 is received through an
opening 54 formed in a pinch weld flange 56 which defines window
opening 14 (see FIG. 10). Stud 52 is then retained within hole 54
by a suitable fastener. In the alternative, stud 52 may be replaced
with a self-anchoring fastener such as a Christmas-tree post or
other similar fastener.
[0048] Distant from hinges 30, and preferably at an opposite end of
panel assembly 12, is at least one mounting member 32. See FIGS. 1,
7 and 8. In a preferred embodiment, mounting member 32 is a
mounting stud having a disk or circular-shaped flange 60 made from
1.0 millimeter thick, 1010 cold rolled steel. Disk 60 has a lower
surface 62 which is concave, and an upper surface 64 which is
convex, as a result of contours formed by several concentric rings
or shoulders 78, 80, respectively, formed in disk 60.
[0049] Formed in disk 60 and spaced equidistantly from each other,
are a plurality of embossments 42 which define stand-offs extending
from lower surface 62 of disk 60 similar to those described above.
Between embossments 42, and preferably spaced equidistantly from
each other, are holes or rotated lances 66 piercing disk 60. Holes
or rotated lances 66 are formed from lower surface 62 through to
surface 64. Rotated lances are formed in such a manner so as to
produce a tag 72 inclined above each hole 66 (FIG. 8a).
[0050] Extending upwardly from surface 64 through a hole 70 located
generally in the center of disk 60 is a stud 68. Stud 68 is
permanently fixed to disk 60 by welding flange 74 to lower surface
62. Flange 74 of stud 68 lies substantially within the uppermost
concave portion 76 of surface 62 to provide a maximum offset
between stud flange 74 and panel 24.
[0051] Disk 60 is bonded to panel 24 in generally the same manner
as hinge 30 described above. The inner surface 22 of panel 24 may
be coated with opaque frit layer 26 either in an area restricted to
that for button stud 60, i.e., slightly larger than the area of
lower surface 62 of disk 60, or is generally coated with the frit
layer 26 as indicated by dash line 26' shown in FIGS. 2 and 3.
Lower surface 62 of disk 60 and frit layer coating 26 are
preferably coated with the desired adhesion-promoting primer
compound 50 as described above. The central portion of concave
surface 62 of disk 60 is permanently bonded to frit layer 26 by
adhesive 46 while the peripheral edge of surface 62 is temporarily
fixtured to frit layer 26 by a thermoplastic hot-melt or other
adhesive 48. Moreover, permanent adhesive 46 mechanically bonds
disk 60 to frit layer 26 by a portion of adhesive 46 extruded
through holes or rotated lances 66. In the case of rotated lances,
extrusion of adhesive 46 is minimized by tab or vane 72 partially
damming or restricting flow of adhesive 46 through each rotated
lance 66. Embossments or stand-offs 42 extending from lower surface
62 provide a space between panel surface 22 or frit layer 26 and
disk 60. Mounting stud or disk 60 is fitted with an appropriate
latching of actuating mechanism (not shown) which is attached to
the inside of window opening 14 and which is used to actuate window
assembly 12 between the open and closed positions via hinges 30.
Such actuators include overcenter hinges, as well as pneumatic,
electric or cable actuators.
[0052] In the alternative to centrally locating adhesive 46 between
disk 60 and frit layer 26 as shown in FIG. 8, thermoplastic
adhesive 48 may be located below stud flange 74 while a bead of
adhesive 46 is placed thereabout. Fixturing of disk 60 is still
obtained by the thermoplastic hot-melt or other adhesive 48 located
in a central portion of disk 60, while the primary adhesive 46 is
then forced outwardly toward the peripheral edges of disk 60 to
provide the maximum bonding surface area. In yet another
alternative, fixturing adhesive 48 may be omitted and both hinge 30
and mounting member 60 may be mechanically fixtured on panel 24
while the primary adhesive 46 cures. Examples of mechanical
fixturing include gravity, mechanical locating, pressing or
clamping including robotic, and manual locating, pressing or
clamping.
[0053] A preferred embodiment of the invention includes hinge 130,
shown in FIGS. 13-15, made from 1.0 millimeter thick, 1010
cold-rolled, half-hardened, epoxy E-coated steel in a U-shape such
that tab portion 138 overlies and is parallel to elongate flange
portion 134. It is preferred that the grain of the steel be
oriented generally perpendicular to the axis of the arcuate,
U-shaped bend. Leg 137 interconnecting flange 134 and tab 138 is
arcuate to provide the spring-like hinge action. Flange 134
contains a plurality of holes 140 which are generally aligned along
the longitudinal axis of the flange at equidistantly spaced
intervals, preferably approximately 8.5 millimeters. Moreover, the
preferred diameter of each hole 140 is about 3.0 millimeters.
[0054] Flange 134 also contains embossments 142 which extend from
lower surface 144 and serve to space flange 134 from panel inner
surface 122. Preferably, embossments 142 extend approximately 1
millimeter from flange 134. As shown in FIG. 14, the outer ends of
flange 134 may curve slightly upwardly before attachment to panel
24'. Such ends are pressed down against panel 24' when fixtured or
secured to the panel. Flange 134 also includes a large hole 143
located directly opposite the portion of tab 138 which receives
stud 152. Hole 143 is provided to allow stud 152 to be placed
through tab 138 so that stud head 153 can be welded or bonded to
tab 138. The opposite end of stud 152 extending from tab 138 is to
be fastened to the vehicle as described below. As shown in FIG. 14,
hinge 130 is curved and preferably applied to panel 24' in a manner
similar to that described for hinge 30 on panel 24. Panel surface
22' preferably includes a primer 50' corresponding to primer 50 and
adhesives 46', 48' may be used in the same manner as adhesives 46,
48 for hinge 30.
[0055] Window assembly 12 may also include a gasket 13 (FIGS. 3 and
9) mounted to inner surface 22 or to pinch weld flange 56 to seal
window assembly 12 in the window opening 14 when panel 24 is in the
closed position. A variety of seals may be used including a bubble
seal such as described in copending, commonly-assigned U.S. patent
application Ser. No. 957,417, filed Oct. 5, 1992, the disclosure of
which is incorporated herein by reference. Other gaskets are
described in copending, commonly-assigned U.S. patent application
Ser. No. 898,094 filed Jun. 12, 1992, and U.S. patent application
Ser. No. 897,764 filed Jun. 12, 1992, both of which are also
incorporated herein by reference. These later two disclosures are
more pertinent to fixed window assemblies than articulated window
assemblies. Yet another sealing arrangement is disclosed in
copending, commonly-assigned U.S. patent application Ser. No.
027,078 filed Mar. 5, 1993, also incorporated herein by
reference.
[0056] In manufacturing window assembly 12, hinges 30, 130 and disk
60 are preferably cleaned with isopropyl alcohol to remove any dirt
and debris. The isopropyl alcohol is also used to clean the glass
surface and/or frit coating 26 which will receive hinges 30, 130
and disk 60. After cleaning of the surfaces, panel surface 22
and/or frit coating 26 receive adhesion-promoting primer compound
50 which is then allowed to dry. Optionally, while
adhesion-promoting primer compound 50 on panel 24 is drying, the
appropriate primer 50 may also be applied to bottom surface 44 of
hinges 30, 130 and to lower surface 62 of disk 60 and allowed to
dry.
[0057] Primer 50 may be applied to hinges 30, 130 and disk 60 in a
variety of ways, including using a dauber, a wipe, spray or other
applicator. In a preferred embodiment, primer 50 is applied to
hinges 30, 130 and disk 60 in one direction with a dauber wipe to
obtain as uniform a coat as possible. If any bare spots appear
after the initial cure time, another coat of primer 50 may be
applied in the same direction. Automated systems such as robotic or
conveyor systems may be used to carry out the application.
[0058] Once primer 50 has dried, the preferred urethane adhesive 46
is applied in a bead to hinges 30, 130 and disk 60. For
single-piece application, adhesive 46 may be applied using a glue
gun, caulking gun or similar applicator. For multi-piece
applications, robotic or conveyor applicators would be more
appropriate. Sufficient room is provided on hinges 30, 130 and disk
60 to receive the hot melt or thermoplastic fixturing adhesive 48
which may be applied using any of the above techniques.
[0059] Soon after thermoplastic adhesive 48 is applied to mounting
members 30, 32, 130, they are located on and engaged with the
surface 22 of panel 24 overlying the frit coating 26. It is
preferred that each mounting member 30, 32, 130 be temporarily held
in place at least until thermoplastic fixturing adhesive 48 has
set. If fixturing adhesive 48 is not used, mounting member 30, 32,
130 most likely will need to remain still relative to panel 24 for
a longer period until bonding adhesive 46 cures. As mentioned
above, this may be achieved by gravity, manual, or mechanical
means. Each panel assembly 12 is then placed in a chamber where the
assemblies are preferably cured at a temperature of approximately
90.degree. F. and a relative humidity greater than 85 percent. The
holes extending through flange 34 of hinge 30, and through disk 60
allow the moisture in the curing chamber to permeate adhesive 46
which results in a net decrease in curing time. It has been found
that a cure time of about six hours for flanges without holes can
be decreased to about four hours for flanges with holes. Following
the cure time in the chamber, the finished panel assemblies 12 are
then ready for shipment to the vehicle manufacturer.
[0060] It is preferred that a moisture-activated urethane adhesive
be used. Window panel assemblies manufactured using the
moisture-activated Morton Yokohama WS70-FK urethane adhesive, and
the Morton Yokohama MS-90 and RC-50 primers, resulted in bonds
between the mounting members and panels which withstood straight
pull test tensional load greater than 250 pounds, and a vast
majority withstood loads greater than 300 pounds. In at least two
instances, the bonds withstood tensional loads on the order of 400
pounds.
[0061] Other tests were conducted on the window assemblies which
included thermal cycle tests, water immersion (80.degree. C.) for
100 and 240 hours, vibration tests, CASS, and impact tests. In
general, the bonds between the mounting members and panel withstood
loads, on average, greater than 225 pounds while loads greater than
250 pounds were achieved on average for panels subjected to
immersion in 80.degree. C. water for 100 and 240 hours. Similar or
better results were achieved on samples subjected to vibration,
CASS and impact tests. Similar results can be achieved using the
family or classes of adhesives described above.
[0062] The above description is considered that of the preferred
embodiments only. Modification of the invention will occur to those
skilled in the art and to those who make or use the invention.
Therefore, it is understood that the embodiments shown in the
drawings and described above are merely for illustrative purposes
and are not intended to limit the scope of the invention, which is
defined by the following claims as interpreted according to the
principles of patent law, including the doctrine of
equivalents.
* * * * *