U.S. patent application number 12/048543 was filed with the patent office on 2008-09-04 for method of making an automotive hardware carrier.
This patent application is currently assigned to International Automotive Components Group North America, Inc.. Invention is credited to James Gregory, Bogdan Radu, John D. Youngs.
Application Number | 20080211136 12/048543 |
Document ID | / |
Family ID | 35098026 |
Filed Date | 2008-09-04 |
United States Patent
Application |
20080211136 |
Kind Code |
A1 |
Radu; Bogdan ; et
al. |
September 4, 2008 |
METHOD OF MAKING AN AUTOMOTIVE HARDWARE CARRIER
Abstract
The present invention provides for an improved hardware carrier
for use in a trim panel assembly, and a method of making the same.
To this end, the hardware carrier includes a body having a front
and back surface and a seal molded to the front surface of the body
for contacting the doorframe structure of a motor vehicle to seal
the carrier thereto. A two-shot molding process utilizing a single
mold assembly is used to form the carrier, with the body being
formed in the first shot and the seal being formed in the second
shot so that the seal is bonded thereto. The molded seal
advantageously is provided with a non-linear configuration, such as
a substantially repeating v-shaped configuration, and includes a
planar top surface. The non-linear configuration of the seal, in
conjunction with the top planar surface, advantageously provides a
substantial surface area for contacting the doorframe to prevent
water leakage within the vehicle.
Inventors: |
Radu; Bogdan; (Dearborn,
MI) ; Youngs; John D.; (Southgate, MI) ;
Gregory; James; (Harrison Township, MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP (LEAR)
2700 CAREW TOWER, 441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
International Automotive Components
Group North America, Inc.
Dearborn
MI
|
Family ID: |
35098026 |
Appl. No.: |
12/048543 |
Filed: |
March 14, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10711119 |
Aug 25, 2004 |
7364218 |
|
|
12048543 |
|
|
|
|
Current U.S.
Class: |
264/255 |
Current CPC
Class: |
B60R 13/0892 20130101;
B60R 13/0243 20130101; B60R 2013/0287 20130101; B29C 45/1676
20130101; B29L 2031/26 20130101 |
Class at
Publication: |
264/255 |
International
Class: |
B29C 45/14 20060101
B29C045/14 |
Claims
1. A method of forming an automotive hardware carrier in a
two-shot: molding operation for use in a door vehicle assembly,
comprising: molding a carrier body having a front and back surface
by injecting a first curable material in a first shot of the
molding operation; forming a mold chamber about a portion of the
front surface of the body; and molding a seal onto the front
surface of the body by injecting a second curable material into the
mold chamber in a second shot of the molding operation wherein the
two shot molding operation is performed in a single mold
assembly.
2. The method of claim 1, wherein the step of molding the seal
further comprises molding the seal to include a non-linear
configuration, the non-linear configuration being defined by
opposing top and bottom surfaces of the seal and opposing first and
second side walls of the seal, the first and second side walls
connecting the top and bottom surfaces, the top surface provided
for contacting a doorframe structure and the bottom surface bonded
to the front surface of the carrier.
3. The method of claim 2, wherein the non-linear configuration
includes at least one of a substantially repeating v-shaped,
s-shaped, and o-shaped configuration.
4. The method of claim 2, wherein the non-linear configuration
further comprises at least a first and second non-linear
configuration, one side of the seal including the first non-linear
configuration and an opposing side of the seal including the second
non-linear configuration.
5. The method of claim 1, wherein the second curable material is a
thermoplastic elastomer and the first curable material is a
thermoplastic material such that the second material bonds to the
first material.
6. The method of claim 1, wherein the two shot molding operation is
performed in a single mold assembly having at least one mold half
provided with a retractable portion.
7. The method of claim 1, wherein the two shot molding operation is
performed in a single mold assembly having at least one mold half
that rotates about an axis.
8. A method of forming an automotive hardware carrier in a two-shot
molding operation for use in a door vehicle assembly, comprising:
providing a mold assembly having a mold including a top and bottom
portion, at least one of the portions adapted to rotate; molding a
carrier body having a front and back surface by injecting into the
mold a first curable material in a first shot of the molding
operation; rotating the at least one of the portions to form a mold
chamber about a portion of the front surface of the body; and
molding a seal onto the front surface of the body by injecting into
the mold chamber a second curable material in a second shot of the
molding operation.
9. The method of claim 8, wherein the step of molding the seal
further comprises molding the seal to include a non-linear
configuration, the non-linear configuration being defined by
opposing top and bottom surfaces of the seal and opposing first and
second side walls of the seal, the first and second side walls
connecting the top and bottom surfaces, the top surface provided
for contacting a doorframe structure and the bottom surface bonded
to the front surface of the carrier.
10. The method of claim 9, wherein the non-linear configuration
includes at least one of a substantially repeating v-shaped,
s-shaped, and o-shaped configuration.
11. The method of claim 9, wherein the non-linear configuration
further comprises at least a first and second non-linear
configuration, one side of the seal including the first non-linear
configuration and an opposing side of the seal including the second
non-linear configuration.
12. The method of claim 8, wherein the second curable material is a
thermoplastic elastomer and the first curable material is a
thermoplastic material such that the second material bonds to the
first material.
13. The method of claim 8, wherein the step of providing a mold
assembly further comprises the top portion being adapted to rotate
about an axis, and wherein the step of rotating the at least one of
the portions further comprises rotating the top portion so that top
portion mates with the bottom portion to form the mold chamber
about the portion of the front surface of the body.
14. The method of claim 13, wherein the top portion further
includes opposing sides with one side including at least one first
shot mold half and the other side including at least one second
shot mold half, and the bottom portion includes at least one mold
half adapted to mate with the at least one first and second shot
mold halves, wherein the step of molding the body further comprises
mating the at least one first shot mold half of the top portion
with the at least one mold half of the bottom portion to define a
first mold and injecting into the first mold the first material,
and wherein the step of rotating the top portion further comprises
rotating the top portion so that the at least one second shot mold
half mates with the at least one mold half of the bottom portion to
form the mold chamber about the portion of the front surface of the
body.
15. The method of claim 14, wherein the at least one first and
second shot mold halves comprise two first and second shot mold
halves and the at least one mold half includes two mold halves,
each of the two first and second shot mold halves adapted to mate
with a corresponding one of the two mold halves of the bottom
portion for molding, in sequence, the body then the seal in the
two-shot molding operation, wherein the step of molding the body
further comprises mating each of the two first shot mold halves of
the top portion with the corresponding one of the two mold halves
of the bottom portion to define first molds and injecting into the
first molds the first material, and wherein the step of rotating
the top portion further comprises rotating the top portion so that
each of the two second shot mold halves mate with the corresponding
one of the two mold halves of the bottom portion to form the mold
chamber about the portion of the front surface of the body.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of pending U.S. patent
application Ser. No. 10/711,119, filed Aug. 25, 2004 (pending), the
disclosure of which is hereby incorporated by reference herein.
This application is also related to U.S. Ser. No. 10/708,411, filed
Mar. 1, 2004 (now U.S. Pat. No. 6,966,594); U.S. Ser. No.
10/708,407, filed Mar. 1, 2004 (now abandoned); and U.S. Ser. No.
10/711,478, filed Sep. 21, 2004 (now abandoned).
FIELD OF THE INVENTION
[0002] The present invention pertains generally to door trim panel
assemblies for vehicle doors and, more particularly, to hardware
carriers for door trim panel assemblies and a method of making the
same.
BACKGROUND OF THE INVENTION
[0003] Vehicle door constructions typically feature a metal
doorframe with a sheet metal outer panel or skin that defines the
door's exterior and an inner sheet metal panel secured to the
doorframe about abutting edges to form a hollow shell. Various door
components, i.e. hardware, including window regulator rails, audio
speakers, latches, and the like, typically are fastened in openings
defined in the inner sheet metal panel. Prior to fastening, the
hardware components may be mounted to a hardware carrier and then
delivered as a separate pre-assembled module to the assembly
line.
[0004] The pre-assembled carrier typically functions as a
non-structural support member wherein the hardware components are
initially mounted to the carrier but later secured to the doorframe
that provides the primary support therefore. These types of
hardware carriers may be composed of polymers including
polypropylene providing for lighter-weighted carriers. In contrast,
carriers may also function as a structural support member that
primarily supports the hardware. For example, window regulator
rails can transfer the weight of the door window pane directly to
the carrier plate. Accordingly, these carrier plates may be formed
from steel or a structural composite material with sufficient
strength to support the door components.
[0005] The carrier, along with the hardware components, can be
fastened to the doorframe with fasteners, and a trim panel
installed thereover to complete the door panel trim assembly and
provide an aesthetically pleasing facade viewed by occupants seated
in the passenger compartment of the motor vehicle. Notably, it can
be desirable to provide the hardware carrier with a seal around the
periphery thereof that cooperates with the inner sheet metal panel
of the doorframe. The seal is intended to provide a water barrier
and prevent water from infiltrating the interior of the door, via
the various door openings, and wetting the interior surface of the
trim panel. One drawback for these types of hardware carriers is in
the current manufacturing thereof.
[0006] The current process for making a hardware carrier having a
seal typically includes first forming the body of the carrier in a
mold. The body then is removed from the mold and a seal material,
e.g. a foam adhesive, is independently applied as a continuous bead
along the top surface of the carrier in a second, separate
operation. Finally, the carrier is placed on a rack within a drying
oven to allow the seal sufficient time to cure.
[0007] As such, under current manufacturing processes, hardware
carriers comprise several different time-consuming steps. These
multiple step processes in turn lead to significant labor costs,
which increases the overall costs of production. In addition, the
foamed, adhesive seal includes a porous, outer skin that can be
easily damaged, such as during installation of the carrier, and has
a tendency to absorb water. The seal also includes a simple, linear
configuration providing a rounded, top surface defining a marginal
surface area for contacting the doorframe. As a result, the seal
has a tendency to provide ineffective sealing between the doorframe
thereby allowing for water leakage into the vehicle.
[0008] There is thus a need for an improved hardware carrier having
a seal for creating a watertight barrier that reduces the labor and
time required for manufacture thereof thereby reducing overall
manufacturing costs.
SUMMARY OF THE INVENTION
[0009] The present invention provides for an improved hardware
carrier for door trim panel assemblies, and a method of making the
same.
[0010] To this end, the hardware carrier includes a body having a
front and back surface, and is adapted so that back surface can be
coupled to a door trim panel such as by fastening means commonly
known in the art, e.g. screws. Notably, the hardware carrier also
may function, itself, as the door trim panel such that the back
surface thereof defines the A-side, or interior side, of the door.
In this fashion, the door trim panel is effectively integrated into
the hardware carrier. The carrier body also is adapted to receive
one or more hardware components, such as window regulators, door
latches, etc., to provide either a structural or non-structural
support member therefore, and further may include one or more
openings to receive the hardware components. The body is formed of
a first material that generally can include a thermoplastic
material such as glass filled polypropylene and the like. The
choice of material can be dependent upon whether the carrier
functions as a structural or non-structural support member for the
hardware components.
[0011] The carrier further includes a seal molded to the front
surface of the body for contacting the door structure, i.e. the
doorframe, of a vehicle to seal the carrier thereto. The seal is
formed of a second material that generally can include a
thermoplastic elastomer or natural rubber material, advantageously
a non-porous, durable rubber material to limit the wear and tear of
the seal, as well as to limit water absorption thereby. Notably,
the second material must be chosen to bond sufficiently to the
first material to allow for molding of the second material thereto.
The seal may be provided with any desired configuration, such as a
simple linear configuration, but advantageously is provided with a
non-linear configuration defined by opposing top and bottom
surfaces of the seal and opposing first and second side walls of
the seal which connect the top and bottom surfaces. The top surface
advantageously includes a planar surface. The non-linear
configuration of the seal, in conjunction with the top planar
surface, provides a substantial surface area for contacting the
doorframe to prevent water leakage within the vehicle.
[0012] In an exemplary embodiment, the hardware carrier includes a
body having a front and back surface and a seal molded to front
surface. The seal advantageously includes SBR rubber. The body
advantageously is composed of glass-filled polypropylene. The seal
further includes a substantially repeating v-shaped configuration
defined by opposing top and bottom surfaces of the seal and
opposing first and second side walls of the seal which connect the
top and bottom surfaces. The top surface includes a planar surface
for contacting the doorframe to prevent water leakage within the
vehicle, and the bottom surface is molded to the top surface of the
body. In another embodiment, the non-linear configuration includes
first and second non-linear configurations such that one side of
the seal defines the first configuration and the other side defines
the second configuration.
[0013] The hardware carrier is formed by a two shot molding
operation. In a first shot of the molding operation, a first
curable material is injected into a mold to form the carrier body
having front and back surfaces. A variety of openings,
additionally, may be formed therein so as to accommodate the
placement of hardware components. The body further is adapted for
coupling to a door structure, i.e. the doorframe, as well as to a
door trim panel if applicable. Next, a mold chamber is formed about
at least a portion of the front surface of the carrier. A second
curable material then is injected into the mold chamber in a second
shot of the molding operation to form the seal whereby the seal
bonds to the body. The seal, advantageously, is provided with a
non-linear configuration such as a substantially repeating
v-shaped, s-shaped, and/or o-shaped configuration. After the second
material has been allowed time sufficient to cure, the hardware
carrier is ready to receive one or more hardware components and/or
is ready to be coupled to a door trim panel, if necessary, and
doorframe of a motor vehicle.
[0014] In an exemplary embodiment, a mold assembly having a mold
including top and bottom portions is provided for molding the
hardware carrier. The top portion of the mold includes opposing
sides with one side having two first shot mold halves and the other
side having two second shot mold halves. The bottom portion of the
mold includes first and second mold halves. One each of the first
and second shot mold halves are adapted to mate with one of the
first and second shot mold halves of the bottom portion.
Specifically, the top portion is adapted to rotate about a central
axis so that one each of the two first and second shot mold halves
of the top portion can mate with a corresponding mold half of the
bottom portion to mold, in sequence, the body then the seal. The
molded seal advantageously includes a substantially v-shaped
configuration and a top planar surface for providing a watertight
barrier.
[0015] By virtue of the foregoing, there is thus provided an
improved hardware carrier including a seal adapted to provide an
effective watertight seal between a doorframe of a motor vehicle,
and a method of making the same.
[0016] The features and objectives of the present invention will
become more readily apparent from the following Detailed
Description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and, together with a general description of the
invention given above, and the detailed description given below,
serve to explain the invention.
[0018] FIG. 1 is a perspective view of an automotive door assembly,
including an embodiment of the hardware carrier of the present
invention;
[0019] FIG. 1A is an enlarged view of the incircle portion 1A
showing the seal of FIG. 1;
[0020] FIG. 1B is a view similar to FIG. 1A showing another
embodiment of the present invention;
[0021] FIGS. 1C-1F are views similar to FIG. 1A showing additional
embodiments of the present invention;
[0022] FIG. 2 is a perspective view of a mold assembly used to form
the hardware carrier of the present invention;
[0023] FIG. 2A is the first in a series of sequential
cross-sectional views of the mold of FIG. 2 taken along the lines
2A-2A illustrating the first shot of the molding operation of the
hardware carrier;
[0024] FIG. 2B is the second in this series of cross-sectional
views;
[0025] FIG. 3 is a perspective view of the mold assembly of FIG. 2
depicting the mold position for forming the seal of the hardware
carrier;
[0026] FIG. 3A is the first in a series of sequential
cross-sectional views of the mold of FIG. 3 taken along the lines
3A-3A illustrating the second shot of the molding operation of the
hardware carrier;
[0027] FIG. 3B is the second in this series of cross-sectional
views;
[0028] FIG. 4A is the first in a series of sequential
cross-sectional views utilizing another embodiment of a mold
assembly to illustrate the second shot of the molding operation of
the hardware carrier;
[0029] FIG. 4B is the second in this series of cross-sectional
views; and
[0030] FIG. 5 is a cross-sectional view of the formed hardware
carrier of FIGS. 3B and 4B removed from the mold.
DETAILED DESCRIPTION OF THE DRAWINGS
[0031] In FIG. 1, there is shown a door vehicle assembly 10 for an
automobile (not shown) including a doorframe 12 and an embodiment
of the hardware carrier 14 of the present invention coupled to a
door trim panel 16 to define a door trim panel assembly 18, i.e. a
door panel.
[0032] The door trim panel 16 is a relatively rigid substrate which
forms at least a portion of the structural support and defines the
general shape of the door trim panel assembly 18. The trim panel 18
may be supported on and releasably secured to the carrier 14 by
fastener means 22 commonly known in the art. These fastener means
22 may include screws, nails, tacks, clips, adhesive, and the like,
and typically are configured for releasing the trim panel 16 from
the carrier 14. Although not illustrated, it should be understood
that the hardware carrier 14 also may function, itself, as the door
trim panel 16 such that a back surface 38 of the carrier 14 defines
an A-side, or interior side, of the door vehicle assembly 10. In
this fashion, the door trim panel 16 is effectively integrated into
the hardware carrier 14 that alone defines the door trim panel
assembly 18.
[0033] The doorframe 12 includes an outer panel 28 or skin that
defines the exterior of the vehicle door assembly 10 and an inner
panel 30 that defines the interior side of the doorframe 12. The
hardware carrier 14 is coupled to the doorframe 12 on the interior
side so that the carrier 14 is supported between the door trim
panel 16 and the doorframe 12. More specifically, the carrier 14
may be supported on and releasably secured to the doorframe 12 by
the fastener means 22. Various door components (not shown), i.e.
hardware, including window regulator rails, audio speakers,
latches, and the like, typically are fastened in openings 32
defined in the inner panel 30.
[0034] As best shown in FIGS. 1 and 5, the carrier 14 includes a
body 34 having a front surface 36 and the back surface 38. The body
34 is adapted so that back surface 38 can be coupled to the door
trim panel 16, when the carrier 14 does not also function as the
door trim panel 16, and so that the front surface 38 can be coupled
to the doorframe 12 by the fastening means 22. The carrier 14 may
receive one or more of the hardware components (not shown) to
provide either a structural or non-structural support member
therefore. More specifically, if the carrier 14 functions as a
non-structural support, the hardware components are initially
mounted to the carrier 14 but later secured to the doorframe 12,
which provides the primary support therefore. In contrast, if the
carrier 14 functions as a structural support member, the carrier 14
primarily supports the hardware. The hardware components may be
secured to the body 34 of the carrier 14 via the fastening means 22
and further may be supported in openings 39 formed therein.
[0035] The body 34 is formed of a first material 40 such as a
thermoplastic material, advantageously polypropylene or
polycarbonate/acrylonitrile butadiene styrene, more advantageously
glass-filled polypropylene. The choice of the first material 40 can
be dependent upon whether the carrier 14 functions as a structural
or non-structural support member for the hardware components such
that sufficient material strength may be necessary to support the
door components when the carrier 14 functions as a structural
support member.
[0036] The carrier 14 further includes a seal 44 molded to the
front surface 36 of the body 34, generally about the periphery
thereof, and is adapted for contacting and compressing against the
doorframe 12 to provide a water barrier and prevent water from
infiltrating the interior of the door assembly 10, via the various
openings 32, 39 of the doorframe 12 and the carrier 14, and wetting
the trim panel 16. The seal 44 is formed of a second material 46
such as a thermoplastic elastomer or natural rubber material,
advantageously, a non-porous, durable rubber such as SBR rubber or
neoprene to limit the wear and tear of the seal 44, as well as to
limit water absorption thereby. Notably, the second material 46
must be able to bond sufficiently to the first material 40 to allow
for molding of the seal 44 to the body 34.
[0037] As best shown in FIGS. 1 and 1A, the seal 44 further
advantageously is provided with a non-linear configuration and,
more specifically, a substantially repeating v-shaped configuration
defined by opposing top and bottom surfaces 52 and 54 of the seal
44 and opposing first and second side walls 56 and 58 of the seal
44 connecting the top and bottom surfaces 52, 54. It should be
understood by the artisan that the seal 44 could include any
desired linear and/or non-linear configuration including, but not
limited to, substantially repeating s-shaped configurations,
o-shaped configurations, combinations thereof, and the like. In
addition, as best shown in FIG. 1B, the artisan should understand
that one side 60 of the seal 44 could include one or more different
non-linear configurations than an opposing side 62. More
specifically, FIG. 1B shows one side 60 including a substantially
repeating v-shaped configuration while the opposing side 62
includes a substantially repeating s-shaped configuration.
[0038] As further shown in FIGS. 1A and 1B, the top surface 52 of
the seal further defines a planar surface 66 while the bottom
surface 54 is bonded to the front surface 36 of the body 34. The
non-linear configuration of the seal 44, in conjunction with the
top planar surface 66, provides a substantial surface area for
contacting the doorframe 12 to prevent water leakage within the
vehicle (not shown).
[0039] As indicated above, the seal 44 alternatively may include a
linear configuration, as best shown in FIG. 1C, wherein the seal 44
has opposing top and bottom surfaces 52, 54 and opposing first and
second side walls 56, 58 connecting the top and bottom surfaces 52,
54. Here, the top surface 52 defines a rounded portion 67 for
contacting the doorframe 12 with the bottom surface 54 being bonded
to the front surface 36 of the body 34.
[0040] In additional embodiments, as shown in FIGS. 1D, 1E, and 1F,
the seal 44 may include opposing top and bottom surfaces 52, 54 and
opposing first and second side walls 56, 58 connecting the top and
bottom surfaces 52, 54 with the top surface 52 being provided with
one or more protrusions 68 extending away therefrom for contacting
the doorframe 12. The protrusion(s) 68 may take on any form or
shape such as a blade, rib, nib, bump, and the like. The bottom
surface 54 of the seal 44 is bonded to the front surface 36 of the
body 34.
[0041] With reference to FIGS. 2-5, methods of making the hardware
carrier 14 of the present invention will now be described.
Specifically, the hardware carrier 14 is formed by a two shot
molding operation wherein a first shot molds the body 34, and
wherein a second shot molds the seal 44.
[0042] To this end, a single mold assembly 70 is shown in FIG. 2
including a mold 72 having a top and bottom portion 74 and 76. The
top portion 74 includes opposing sides 78 and 80 with one side 78
having first shot mold halves 84a and 84b and the opposing side
having second shot mold halves 86a and 86b. The bottom portion 76
includes first and second mold halves 88a and 88b with each mold
half 88a, 88b adapted to mate with one each of the first and second
shot mold halves 84a, 84b and 86a, 86b. The top portion 74 further
is adapted to rotate about a central axis 90 so that each of the
first and second shot mold halves 84a, 84b and 86a, 86b of the top
portion 74 can mate with the corresponding mold halves 88a, 88b of
the bottom portion 76 to mold, in sequence, first the body 34 then
the seal 44 of the hardware carrier 14. It should be understood by
the artisan that any number of cooperating mold halves (i.e. more
or less than shown) may be provided within the top and bottom
portions 74, 76 for molding the hardware carrier 14. In addition,
the top portion 74 may rotate in any manner suitable so that the
desired number of mold halves cooperate to produce the carrier
14.
[0043] While the first and second shots of the molding operation
are further described below utilizing the cross-sectional views of
FIGS. 2 and 3, i.e. mold halves 84b, 86b, and 88b, it is understood
that the first and second shot molding process occurs in the same
fashion with respect to mold halves 84a, 86a, and 88a. Accordingly,
as best shown in FIGS. 2A and 2B, the first shot mold half 84b of
the top portion 74 mates with its respective mold half 88b of the
bottom portion 76 to define a first mold 94 having a cavity 96
therein. In a first shot of the molding operation, the first
curable material 40 is injected through a channel 98 into the
cavity 96 of the first mold 94 to form the carrier body 34 having
front and back surfaces 36, 38. The first curable material 40 may
be a thermoplastic material, advantageously polypropylene or
polycarbonate/acrylonitrile butadiene styrene, most advantageously
glass-filled polypropylene. A variety of openings 39 (See FIG. 3)
may be formed therein so as to accommodate the placement of
hardware components (not shown) and for coupling of the carrier 14
to the doorframe 12, as well as to the door trim panel 16 (if
applicable). Coupling may be accomplished by the use of the
fastener means 22.
[0044] With further reference to FIG. 3, the mold 72 next is opened
and the top portion 74 is rotated about the central axis 90 so that
the second shot mold halves 86a, 86b of the top portion 74 are
facing the mold halves 88a, 88b of the bottom portion 76. As
further shown in FIGS. 3A and 3B, the second shot mold half 86b
then is mated with its respective mold half 88b to form a mold
chamber 102 about a portion 104 of the front surface 36 of the body
34. The second curable material 46 then is injected through a
channel 106, in a second shot, into the mold chamber 102 to form
the seal 44, generally around the periphery of the body 34. The
second curable material 46 is a thermoplastic elastomer or natural
rubber material, advantageously a non-porous, durable rubber such
as SBR rubber or neoprene. Notably, the second curable material 46
must be able to mold, i.e. bond, to the first material 40.
[0045] With respect to the molding operation, one may further mold
the hardware carrier 14 by utilizing other methods such as by
providing a mold assembly 108 (See FIGS. 4A and 4B) with a
retractable portion 110, i.e. a slider. More specifically, as shown
in FIGS. 4A and 4B, the mold assembly 108 may be provided with a
mold 112 including a bottom portion 114 having a mold half 116a and
a top portion 118 including a corresponding mold half 116b provided
with the slider 110. It should be understood by the artisan that
any number of cooperating mold halves may be provided within the
top and bottom portions 114,118 for molding the hardware carrier
14. The mold halves 116a, 116b are adapted to mate to form the
carrier body 34, as explained above, then the slider 110 is
retracted to form a mold chamber 120 about a portion 122 of the
front surface 36 of the body 34 for molding the seal 44 thereto.
Notably, the slider 110, in FIGS. 4A and 4B, is shown already
retracted. As shown in FIG. 4B, the second curable material 46, as
similarly explained above, is injected through a channel 124, in
the second shot, into the mold chamber 120 to form the seal 44,
generally around the periphery of the body 34.
[0046] As further shown in FIGS. 5 and 1A, the molded seal 44
includes the non-linear configuration, i.e. the substantially
repeating v-shaped configuration, defined by the opposing top and
bottom surfaces 52, 54 and the opposing first and second side walls
56, 58 connecting the top and bottom surfaces 52, 54. The bottom
surface 54 is bonded to the front surface 36 of the carrier 14 and
the top surface 52 includes the planar surface 66 for contacting
the doorframe structure 12 to seal the carrier 14 thereto.
Accordingly, other linear and/or non-linear configurations may be
molded such as repeating s-shaped configurations, o-shaped
configurations, and the like, as well as combinations of
configurations. In addition, the mold assembly 70 may provide a
seal 44 (See FIG. 1B) wherein one side 60 of the seal 44 could
include one or more different non-linear configurations from the
opposing side 62 of the seal 44.
[0047] After the second material 46 has been allowed time
sufficient to cure, the mold 72 may be opened and the carrier 14
ejected therefrom. The formed carrier 14 includes the body 34 and
the seal 44 molded thereto. The formed hardware carrier 14 now is
ready to receive one or more hardware components (not shown) and/or
is ready to be coupled to a door trim panel 16 and doorframe
structure 12 of a motor vehicle. Accordingly, the molding operation
of the present invention may be continuously performed utilizing a
single mold assembly 70 to provide an improved automotive hardware
carrier 14 including a seal 44 provided with one or more various
shapes or configurations for creating a watertight barrier.
[0048] While the present invention has been illustrated by the
description of the various embodiments thereof, and while the
embodiments have been described in considerable detail, it is not
intended to restrict or in any way limit the scope of the appended
claims to such detail. Additional advantages and modifications will
readily appear to those skilled in the art. The invention in its
broader aspects is therefore not limited to the specific details,
representative apparatus and methods and illustrative examples
shown and described. Accordingly, departures may be made from such
details without departing from the scope or spirit of Applicant's
general inventive concept.
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