US20060012218A1 - Sealing systems and related methods for automotive interior trim panels and the like - Google Patents
Sealing systems and related methods for automotive interior trim panels and the like Download PDFInfo
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- US20060012218A1 US20060012218A1 US11/178,718 US17871805A US2006012218A1 US 20060012218 A1 US20060012218 A1 US 20060012218A1 US 17871805 A US17871805 A US 17871805A US 2006012218 A1 US2006012218 A1 US 2006012218A1
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- United States
- Prior art keywords
- trim panel
- panel
- sealing
- door panel
- water shield
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Links
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
- B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J5/00—Doors
- B60J5/04—Doors arranged at the vehicle sides
- B60J5/0412—Lower door structure
- B60J5/0418—Water or sound barrier, e.g. watershields or seals between dry/wet compartment, sound or vibration dampers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0237—Side or rear panels
- B60R13/0243—Doors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0892—Insulating elements, e.g. for sound insulation for humidity insulation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2581/00—Seals; Sealing equipment; Gaskets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
Abstract
A combined trim panel and water shield includes a water shield having opposite first and second surfaces, and is of a size and shape to generally conform to a door panel and a trim panel to be protected. The trim panel is configured to cover a vehicle door panel and has a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. A first sealing layer, applied in a predetermined pattern, engages the first surface of the water shield and the second surface of the trim panel. A second sealing layer, applied in a predetermined pattern, engages the second surface of the water shield. In a further aspect, a sealing system is provided for application to a vehicle interior trim panel to prevent the entry of water or dust into an interior compartment of the vehicle. The system includes a trim panel configured for covering a vehicle door panel wherein the trim panel has a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. At least one compressible sealing member engages the trim panel and provides a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.
Description
- The present application is a divisional application of U.S. Ser. No. 10/137,542 filed May 2, 2002, which claims the benefit of the filing date of U.S. Provisional Application No. 60/288,379 filed on May 3, 2001, the disclosures of which are hereby incorporated by reference.
- The present invention relates generally to sealing or gasketing and, more particularly, to systems and methods for sealing an interior compartment of a vehicle against entry of water, wind, noise, dust, or other environmental contamination. The system and method of the invention are particularly adapted for use in an automobile and will be described with particular reference thereto. However, it will be appreciated that the invention has broader applications and may be used to provide a water-tight seal in many different environments, such as other types of overland vehicles, watercraft, aircraft, washing machines, automatic dishwashers, and so forth.
- The metal inner panel of a vehicle door has a plurality of openings and holes therein for mounting certain accessories and mechanisms in the door and for providing access to such accessories and mechanisms. By way of example, the inner panel of a vehicle door may have openings and holes for mounting such items as window operating mechanisms, locks and lock switches, side-view mirror controllers, loudspeakers, and so forth.
- A decorative interior trim panel and arm rest are conventionally applied over the inner panel of a vehicle door. Commonly, a water deflector or shield is applied between the inner door panel and interior door trim for preventing entry of water, dirt, and the like into the vehicle body or causing damage to the interior door trim itself. Heretofore, the normal practice has been to secure a water deflector over the inner door panel prior to installing the trim panel.
- Therefore, as recognized by the present invention, there exists a need in the art for a combined trim panel and water deflector or shield which permits the water deflector to be installed simultaneously with the trim panel. As further recognized by the present invention, there exists a need in the art for a door trim sealing system which obviates the need for a separate water deflector or shield.
- In a first aspect, a combined trim panel and water shield includes a water shield having opposite first and second surfaces, and which is of a size and shape to generally conform to a door panel and a trim panel to be protected. The trim panel is configured to cover a vehicle door panel and has a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. A first sealing layer, applied in a predetermined pattern, engages the first surface of the water shield and the second surface of the trim panel. A second sealing layer, applied in a predetermined pattern, engages the second surface of the water shield.
- In a second aspect, a method for the production of a combined water shield and trim panel structure is provided. The method comprises providing a trim panel which is configured to cover a door panel, and which has a first surface configured to face an interior compartment of a vehicle. A sealing member, which may be a flat or shaped sheet of material having opposite first and second surfaces is also provided. The sealing member is of a size and shape to generally conform to the trim panel and the door panel. A first sealing material is applied to the first surface of the sheet in a first predetermined pattern, and a second sealing material is applied to the second surface of the sheet in a second predetermined pattern. The sheet and the trim panel are aligned so that the first surface of the sheet is in facing relation with a second surface of the trim panel opposite the first surface thereof. The trim panel is contacted with the first sealing member to attach the trim panel to the water shield. In a more limited aspect, a protective liner of plastic or other material is removably attached to the second sealing layer and is removed when the combined water shield/trim panel is installed on the door.
- In a third aspect, a sealing system for application to a vehicle interior trim panel for preventing the entry of water or dust from entering an interior compartment of the vehicle includes a trim panel configured for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. The sealing system further includes at least one compressible sealing member engaging the trim panel and providing a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.
- In a fourth aspect, a method for sealing a vehicle door interior trim panel against entry of water or dust includes attaching at least one compressible sealing member to a trim panel such that the at least one sealing member is positioned to provide a sealing interference between the door panel and the trim panel when the trim panel is installed on the door panel. The trim panel retaining the at least one compressible sealing member is then installed onto the door panel.
- In a fifth aspect, a combined trim panel and water shield assembly for a vehicle includes a trim panel configured for covering a vehicle door panel, the trim panel in facing relation to an interior compartment of the vehicle. A foam layer engages and is sandwiched between the trim panel layer and the door panel. Optionally, a sealing layer for providing a seal between the flat sheet and the inner door panel, such as an adhesive or a compressible seal, is provided.
- In a sixth aspect, a stacked plurality of sealing systems is provided. The stacked plurality includes a first sealing system including a trim panel adapted to cover a vehicle door panel and a sealing member engaging the trim panel and providing a sealing interference between the vehicle door panel and the trim panel. The stacked plurality also includes a second sealing system positioned adjacent the first sealing system. The second sealing system includes a trim panel adapted to cover a vehicle door panel and a sealing member engaging the trim panel. The stacked plurality of sealing systems further comprises a releasable protective liner disposed between the first and second sealing systems.
- In a seventh aspect, a combined trim panel and water shield assembly includes a trim panel configured for covering a vehicle door panel, a generally flat non-compressible water shield, and an adhesive layer engaging the flat sheet to the trim panel.
- In an eighth aspect, a combined trim panel and water shield assembly includes a trim panel configured for covering a vehicle door panel, a generally flat non-compressible water shield, and an adhesive layer engaging the flat sheet and adapted to engage the vehicle door panel.
- One advantage of the present invention is found in that combining the water shield and trim panel or, alternatively, eliminating the water shield, reduces the number of parts needed to make the automobile and simplifies assembly of the automobile.
- Further advantages of the present invention reside in its ease, accuracy, and repeatability of installation.
- Another advantage is that many add-on parts used in door trim can be eliminated, thereby reducing noise, vibration, and harshness (NVH) and buzz, squeak, and rattle (BSR) issues.
- Yet another advantage resides in the fact that by eliminating a separate water shield component, additional door components can be packaged to the trim panel.
- Still a further advantage is found in that the door sealing system is self-locating and eliminates the need for part application in the assembly plant.
- Another advantage is found in that rework, repair, and service are made easier.
- Another advantage of the invention resides in its ease of disassembly, recycling, and the like, e.g., at the end of vehicle life.
- Yet another advantage resides in that the number of parts can be reduced by adding them to the module.
- Still further benefits and advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
- It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
- The following detailed description may be best understood when read in reference to the accompanying drawings wherein similar reference characters denote similar elements throughout the several views.
-
FIG. 1 shows an automobile door employing the combined water deflector and trim panel formed according to a first embodiment of the present invention. -
FIGS. 2A-2F are cross-sectional views of six different embodiments of the combined water shield and trim panel taken along line 2-2 ofFIG. 1 . -
FIG. 3 is a cross-sectional view of an embodiment similar to that shown inFIG. 2D , illustrating a plurality of adhesive-coated water shields layered between successive carrier sheets. -
FIG. 4 is an exploded view of an automobile door employing the sealing system formed according to a second embodiment of the invention. -
FIG. 5A is a cross-sectional view taken along line 5-5 ofFIG. 4 . -
FIGS. 5B-5F illustrate alternative embodiments to that shown inFIG. 5A . -
FIGS. 6-9 are fragmentary cross-sectional views of some sound-absorbing combined trim panel/water deflectors contemplated by the present invention. -
FIG. 1 andFIGS. 2A-2F show atypical vehicle door 10 incorporating a combined trim panel andwater shield construction 18 in accordance with the subject invention. Thedoor 10 includes inner andouter door panels window 16 is shown fordoor 10 and moves into the space defined between the inner and outer door panels in a known manner. - Referring now to
FIG. 2A , a fragmentary cross-sectional view is shown of a combined interior trim panel andwater shield 18 a of the present invention. The combined unit is peripherally shaped to substantially cover theinner door panel 12. The combined trim panel andwater deflector 18 a includes decorativetrim panel layer 20 and compressiblewater shield layer 24 disposed between thesheet metal 12 and the decorativetrim panel 20. Optionally, thecompressible shield 24 can be placed on or secured to thetrim panel 20 at a centralized location and installed onto the door as a single unit. At least a portion of thewater shield 24 has a cross-sectional thickness, which may be varied or uniform, which is greater than the width of the space to be sealed, such that the material is compressed when the trim panel is installed on the door, the compression providing a sealing pressure between thedoor panel 12 and thetrim panel shell 20. Preferably, the compressed areas form a seal about the door panel periphery or other areas where prevention of water entry is desired. - Referring now to
FIG. 2B , combined trim panel andwater deflector 18 b includes decorativetrim panel layer 20 and a compressiblewater shield layer 24. A sealing layer orcoating 26 is disposed between thecompressible shield member 24 and thedoor panel 12. Thesealing layer 26 preferably forms a continuous ribbon or bead about the periphery of thewater shield layer 24, although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding or sealing the middle area of thedeflector layer 24 with respect to theinner door panel 12. The sealingmaterial 26 may comprise an adhesive or a compression-type gasket or seal formed of a compressible or resilient material, such as a formed-in-place (FIP) gasket. - Optionally, the combined
unit 18 b can be assembled at a centralized location and installed onto the door as a single unit. A protective sheet of material (not shown) can be removably attached over thelayer 26 for handling and is removed prior to installing the unit. Again, the sealingmaterials - Referring now to
FIG. 2C , combined trim panel andwater deflector 18 c includes decorativetrim panel layer 20 and a compressiblewater shield layer 24. A sealing layer orcoating 22 is disposed between thecompressible shield member 24 and thetrim panel shell 20. Thesealing layer 22 preferably forms a continuous ribbon or bead about the periphery of thewater shield layer 24, although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding or sealing the middle area of thedeflector layer 24 with respect to thetrim panel 20. The sealingmaterial 22 may comprise an adhesive or a compression-type gasket or seal formed of a compressible or resilient material, such as a formed-in-place (FIP) gasket. - Again, the combined
unit 18 c can optionally be assembled at a centralized location and installed onto the door as a single unit. Again, the sealingmaterials - Referring now to
FIG. 2D , a combined trim panel andwater deflector 18 d includes a decorativetrim panel layer 20 and awater shield layer 24 which are adhesively bonded by afirst seal layer 22. The combined trim panel andwater shield 18 d further includes asecond sealing layer 26 which affixeswater shield layer 24 to theinner door panel 12. The sealing layers 22 and 26, which may be the same or different, preferably each form a continuous ribbon or bead about the periphery of thewater shield layer 24, although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding the middle area of thedeflector layer 24 to theinner door panel 12 and/ortrim panel layer 20. - The combined
unit 18 d can optionally be assembled at a centralized location for installation as a single unit. A protective sheet of material (not shown) can be removably attached over thelayer 26 for handling and is removed prior to installing the unit. The sealingmaterials - Referring now to
FIG. 2E , a combined trim panel andwater deflector 18 e includes decorativetrim panel layer 20 and a rigid, non-compressiblewater shield layer 24′, e.g., formed of a rigid plastic or other material. A sealing layer orcoating 26 is disposed between therigid shield member 24′ and thedoor panel 12. Thesealing layer 26 preferably forms a continuous ribbon or bead about the periphery of thewater shield layer 24, although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding or sealing the middle area of thedeflector layer 24 with respect to theinner door panel 12. The sealingmaterial 26 may comprise an adhesive or a compression-type gasket or seal formed of a compressible or resilient material, such as a formed-in-place (FIP) gasket. - Optionally, the combined
unit 18 e can be assembled at a centralized location and installed onto the door as a single unit. A protective sheet of material (not shown) can be removably attached over thelayer 26 for handling and is removed prior to installing the unit. Again, the sealingmaterial 26 is of a size and configuration such it is compressed to form a sealing engagement between thedoor panel 12 and therigid shield 24′ when theunit 18 e is installed on the door, e.g., at the door panel periphery or other areas where prevention of water entry is desired. - Referring now to
FIG. 2F , a combined trim panel andwater deflector 18 f includes a decorativetrim panel layer 20 and awater shield layer 24″ which are adhesively bonded by afirst seal layer 22. The combinedunit 18 f further includes asecond sealing layer 26 which affixeswater shield layer 24″ to theinner door panel 12. The sealing layers 22 and 26, which may be the same or different, preferably each form a continuous ribbon or bead about the periphery of thewater shield layer 24″, although use of discontinuous bands is also contemplated. The sealing material may be provided to additional areas within the peripheral bands to assist in holding the middle area of thedeflector layer 24″ to theinner door panel 12 and/ortrim panel layer 20. - The combined
unit 18 f can optionally be assembled at a centralized location for installation as a single unit. A protective sheet of material (not shown) can be removably attached over thelayer 26 for handling and is removed prior to installing the unit. Again, the sealingmaterials - In reference now to
FIGS. 2A-2F , the combined trim panel and water shield of each of the above-describedembodiments 18 a-18 f functions to deflect water entering the space between the inner and outer door panels. The water is thus kept within the door assembly for drainage out through conventional bottom drain openings instead of wetting the inner doortrim panel layer 20 or entering the interior compartment of the vehicle. - The
trim panel layer 20 generally comprises a structural material, such as a plastic, metal, composite, laminate, or other material generally used in the construction of automotive interior trim panels, which is molded or otherwise formed to the needed functional and aesthetic shape. The trim panel layer may further include decorative materials, such as cloth, leather, plastic, foam, vinyl, or other material generally used in the construction of automotive interior trim panels. - In the depicted embodiments of
FIGS. 2A-2D , thewater shield layer 24 comprises a foam material, such as open- or closed-cell polyurethane, polypropylene, polyethylene, and so forth. In the embodiment depicted inFIG. 2E , thewater shield layer 24′ comprises a non-compressible and generally nonflexible or rigid plastic material. InFIG. 2F , thedeflector layer 24″ is a polymer film, such as polyethylene film, corona surface-treated polyethylene film, and the like. - In the embodiments of
FIGS. 2B-2F , having one or both of the sealing coatings orbands FIGS. 2D and 2F , wherein both of thelayers - When a compression type seal is employed as the
layer 22 and/or 26, it may have sufficient tack to adhere to the water shield layer or, alternatively, it may be adhesively bonded to the water shield layer by, for example, using an adhesive, such as a pressure-sensitive adhesive. - A compression-type seal employed in conjunction with the present invention comprises a flexible, resilient, or compressible material. Such materials include flexible plastic, rubber, elastomers, silicone, foam rubber, synthetic foam materials, gels, and the like. Such seals or gaskets can be formed separately, or more preferably, can be dispensed directly onto the water deflector in an uncured state and allowed to cure. A preferred compression seal comprises a polyurethane foam.
- As illustrated in
FIGS. 2A-2D , thewater deflector substrate 24 comprises a compressible or resilient material, such as a foam or the like, and one or both of the sealing layers 22 and 26 can optionally be omitted. Finally, when a rigid, non-compressiblewater shield substrate 24″ is employed (FIG. 2F ), the first and second sealing layers 22 and 26 are selected from adhesives and compression-type seal or gasket materials, and may the same or different. When the flexible,non-compressible substrate 24′ is used (FIG. 2E ), sealinglayer 22 on the trim panel side is omitted and sealinglayer 26 on the door panel side is either an adhesive or a compression-type sealing layer. The combinations of sealing layers for compressible, rigid non-compressible, and flexible non-compressible substrates are listed in TABLE 1 below.TABLE 1 Coating on Trim Coating on Door Panel Side Panel Side Compressible None None Water Shield None Adhesive Substrate None Compression Seal Adhesive None Adhesive Adhesive Adhesive Compression Seal Compression Seal None Compression Seal Adhesive Compression Seal Compression Seal Flexible, Adhesive Adhesive Non-compressible Adhesive Compression Seal Water Shield Compression Seal Adhesive Substrate Compression Seal Compression Seal Rigid, None Adhesive Non-compressible Water None Compression Seal Shield Substrate - In one preferred embodiment, the
layer 22 is a permanent pressure-sensitive adhesive and thelayer 26 is a compression-type seal. This embodiment provides the advantage of allowing easy removal and replacement for door access and repair. In another preferred embodiment, thelayer 22 comprises a first adhesive, such as a non-permanent or removable pressure-sensitive adhesive, andlayer 26 comprises a second adhesive having a greater tenacity or tack than the first adhesive, which may be, for example, a nonpermanent adhesive having a higher tack or tenacity than the first or a substantially permanent adhesive. Both of these embodiments allow the trim panel and water shield to be applied as a single unit, thus eliminating the need for separate water shield application during assembly. - In construction, one or both of the first and second sealing layers, if present, are applied to the respective side of the water shield substrate, each in a preselected pattern corresponding to a desired configuration, and serve as means of attachment to aligned or mating surfaces of the
trim panel layer 20 and the inner doorpanel sheet metal 12, respectively. - The water shields can be attached to the trim panel at a central location and the combined
article 18 then applied to thedoor 10 as a single unit at the assembly plant. In embodiments 2B and 2D-2F, which have alayer 26 on the side of the substrate intended to face the sheet metal door panel, a protective liner, such as a release coated sheet or film, is preferably removably applied over thelayer 26 for protection during processing and handling. The protective liner is a polyethylene or other plastic sheet, preferably release coated with a release agent, such as a silicone-based release material. The protective sheet is then removed prior to installation at the assembly plant. Thetrim panel shell 20 serves as a protection for thelayer 22 if present. If the water deflectors are not preattached to the trim panel, thelayer 22 can be lined with a protective sheet in like manner. - Alternately, the units can be stacked into pads, with protective liners removably placed over the adhesive or sealing layers as necessary to separate adjacent units. As shown in
FIG. 3 , the water shields 24 with oppositely disposed first and second sealing layers are removably sandwiched betweenprotective liners 28 to form a stack or pad of a desired number of water deflectors for processing, shipping, handling, and storage until use. - Referring now to
FIGS. 4 and 5 A-5F, there is shown an exploded view of avehicle door 40 employing a sealing system formed in accordance with a second aspect of the subject invention in which adoor panel 42 is sealed with asubstrate 44 which uses sealingelements - The
door 40 generally comprises anouter panel 44 and aninner panel 42 suitably secured to theouter panel 44, such as by welding along the peripheral edge ofpanel 42, the panels defining an internal chamber for accommodating various internal door mechanisms. - A
trim panel 50 is installed over the inner panel to form the interior surface of thedoor 40 and to overlie the various door-mounted components. The trim panel is attached to the inner door panel using clips, screws, snap-type fasteners, and the like, in a known manner. Awater shield 54, which may be a flat or shaped sheet of material, is located between thedoor panel 42 and thetrim panel layer 50. Various openings, e.g.,openings substrate 54 for loudspeaker, wire, door handle, lock rod, and other attachment and pass-through points. In the embodiment ofFIGS. 4 and 5 A, afirst sealing material 52, which may be an adhesive or a compression-type gasket material, is disposed between thedeflector 54 and thetrim panel 50. Asecond sealing layer 56 which is also an adhesive or a compression-type gasket material, and which may be the same as or different than thelayer 52 is located between thepanel 42 and thesubstrate 54. - The compression seal or
adhesive layers inner panel 42 includes aflat region 70 generally following the peripheral edge thereof. In this manner, the inner door panel can be formed with a functionally needed shape as determined by the particular door configuration and which can be generally uneven so long as atleast track 70 is generally flat for sealingly engaging the sealing system of the present invention. - Referring to
FIG. 5A , the sealing system includes aflexible substrate 54, e.g., a flexible plastic film, having afirst sealing layer 52 facing thetrim panel 50 and asecond sealing layer 56 disposed on the opposite side of thesubstrate 54 and facing thetrack 70 of the door panel. Thetrim panel 50 further includes a raisedpressure rib 76 molded thereinto for retaining and further compressing the sealingmember 52. - Referring now to
FIG. 5B , the sealing system includes acompressible substrate 54′, e.g., a compressible foam material. Thesubstrate 54′ is disposed between thetrim panel 50 and thetrack 70 of the door panel. Thetrim panel 50 further includes a raisedpressure rib 76 molded thereinto for retaining and further compressing thesubstrate 54′. - Referring now to
FIG. 5C , the sealing system includes acompressible substrate 54′ engagingtrim panel 50 which includes a raisedpressure rib 76 molded thereinto for retaining and further compressing thesubstrate 54′. Asealing layer 56, such as an adhesive or compression-type seal, engages the opposite side of thesubstrate 54′ and thetrack 70 of theinner door panel 42. - Referring to
FIG. 5D , the sealing system includes acompressible substrate 54′ having afirst sealing layer 52 facing thetrim panel 50 and asecond sealing layer 56 disposed on the opposite side of thesubstrate 54′ and facing thetrack 70 of the door panel. Thetrim panel 50 further includes a raisedpressure rib 76 molded thereinto for retaining and further compressing the sealingmember 52. - Referring to
FIG. 5E , the sealing system includes acompressible substrate 54′ having asealing layer 52 facing thetrim panel 50, a raisedpressure rib 76 formed in the trim panel surface retaining and further compressing the sealingmember 52. The opposite surface of thesubstrate 54′ sealingly engages thetrack 70 of the door panel. - Referring now to
FIG. 5F , the sealing system includes a rigid,non-compressible substrate 54″ facing thetrim panel 50 and a sealingmember 56 engaging the raisedportion 70 of thedoor panel 42. - In each of the embodiments shown in
FIGS. 5A-5F , the trim panel and theappropriate sealing elements - Of course, in each of the embodiments shown in
FIGS. 5A-5F , thetrack region 70 can be omitted where the door panel itself otherwise provides an adequate sealing surface. - Although a door and sealing system of given configuration are illustrated in the depicted exemplary embodiment, the present invention is not limited to any particular configuration. It will be recognized that other geometric shapes, patterns, and spatial orientations can be used to accommodate different applications or installations without in any way departing from the overall intent or scope of the invention. Likewise, continuous gaskets or beads of material need not be used, and the seals may instead comprise one or more discontinuous strips.
- When a compression-type seal is used as a sealing
member 52 and/or 56, the cross-sectional shape of the gasket can be modified to accommodate the particular surface to be sealed. Likewise, the resiliency of the gasket material can be selected to obtain a desired degree of sealing force. Instead of a generally solid gasket as shown in the illustrated embodiment, a hollow or tubular compression seal, e.g., having a flexible sealing portion and compressible walls, may be used. - A fragmentary cross-sectional view of a combined trim panel/
water deflector system 80 formed in accordance with another embodiment of the development is illustrated inFIG. 6 . The combined trim panel andwater deflector 80 includes atrim panel layer 20, theoutward surface 82 of which faces an interior compartment of a vehicle and is peripherally shaped to substantially cover aninner door panel 12. Afoam layer 86 is sandwiched between thetrim panel 20 and asubstrate 88. Thefoam layer 86 is preferably an open-cell foam material, most preferably a polyurethane foam material, and provides a sound-absorbing function to reduce wind noise and other noise from entering the interior compartment of the vehicle. Since thewater deflector 88 is attached directly to the trim panel, fewer holes in the part are required, thus improving air, dust, and sound sealing than conventional water deflectors. The foam material is adhesively bonded to thesubstrate 88 and thetrim panel 20. - The
foam layer 86 is advantageously compression cut to provide a nonplaniform surface which is complimentary to and mating with theinward surface 84 of thetrim panel 20. The thickness of the foam layer is thus varied so as to provide a surface which matches theinward surface 84 of thetrim panel 20, i.e., the foam surface has raised areas which engage complimentary recesses or depressions in the trim panel and vice versa. - The variable thickness in the
foam layer 86 can be formed using a compression cutting technique. In this manner, the foam thickness can be varied in any configuration from full thickness down to near zero. The sheet is compressed between a smooth roller and a profiled roller or plate to selectively compress the foam different amounts in different regions. A cutting blade is positioned to cut the foam just as it exits the nip. In this manner, the regions that are compressed are not cut or are minimally cut and the uncompressed areas are cut more deeply. - A
sealing layer 90 engagessubstrate 88 andinner door panel 12. In one embodiment, the sealing layer is a pressure sensitive adhesive, preferably forming a continuous ribbon or bead about the periphery of the combined trim panel andwater shield 80. The use of discontinuous bands is also contemplated, and the sealingmaterial 90 may be provided to additional areas within the peripheral bands. - In a second embodiment, sealing
layer 90 comprises a compression-type seal or gasket, preferably forming a continuous seal about the periphery of the combined trim panel andwater shield 80. The use of discontinuous sealing portions is also contemplated, however. The sealingmaterial 90 may be provided to additional areas within the periphery of the area to be sealed. Preferably, the gasket is a formed-in-place (FIP) type of gasket, such as polyurethane foam or other material which is dispensed as a bead of material in its uncured state and then allowed to cure. - Irrespective of the material comprising the
sealing layer 90, the trim panel is fastened to theinner door panel 12 using mechanical fasteners, such as conventional trim panel clips or the like (not shown). The thickness of thefoam layer 86 is such that it will be compressed when the combinedunit 80 is installed on the door, the compression providing a sufficient degree of pressurization to effect a seal. - Although the
sealing layer 90 can be formed in situ at the assembly plant, it is preferable to apply thelayer 90 at a centralized location. When thesealing layer 90 is preapplied, it is preferable to removably attach a protective sheet of material. When sealinglayer 90 is a pressure sensitive adhesive, including both nonpermanent and substantially permanent pressure sensitive type adhesives, a release coated sheet of plastic material can advantageously be employed as the protective sheet. - Since the mechanical attachments found on the
trim panel portion 20 are used to locate the sealing system, operator sensitivity and variation in part installation is eliminated. - In a preferred embodiment, a first adhesive is used between the
foam layer 86 and thesubstrate 88, and a second adhesive having a higher tack or tenacity than the first is used between thefoam layer 86 and thetrim panel 20. Thefoam layer 86 andtrim panel 20 are thus easily removable from thesubstrate 88, e.g., for servicing, replacement, and so forth. When an adhesive is used as thesealing layer 90, the tack or tenacity of the adhesive 90 is likewise higher than the first adhesive. - In an alternate embodiment, an adhesive is used as the
sealing layer 90 which has a lower tack or tenacity than the adhesive bonding thefoam layer 86 to thetrim panel shell 20 as well as the adhesive bonding thefoam layer 86 to thesubstrate 88. In this manner, the combined trim panel andwater shield 80 is removable as a single unit for servicing, repair, or replacement. - In
FIG. 7 , there is illustrated an embodiment substantially as described in reference toFIG. 6 , but wherein thesealing layer 90 is eliminated. In the embodiment ofFIG. 7 , the compression of thefoam material 86 that results when the unit is installed on the door effects a sealing engagement betweensheet metal layer 12 andsubstrate layer 88. - In
FIGS. 8 and 9 , there are shown embodiments which are as described above in reference toFIGS. 6 and 7 , respectively, except that thesubstrate 88 is omitted. - The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. The forms hereinbefore described are merely explanatory and exemplary and it is intended that the invention be construed as including all such modifications and alterations.
Claims (58)
1. A combined trim panel and water shield assembly for a vehicle comprising:
a trim panel configured for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface;
a generally flat water shield having opposite first and second surfaces and having a size and shape to generally conform to a surface of said trim panel and a surface of said door panel;
a first adhesive layer engaging the first surface of the flat sheet and the second surface of the trim panel, the first adhesive layer applied in a first predetermined pattern; and
a second adhesive layer engaging the second surface of the flat sheet and applied in a second predetermined pattern.
2. The combined trim panel and water shield assembly of claim 1 , wherein the water shield comprises a sheet of flexible plastic material.
3. The combined trim panel and water shield assembly of claim 1 , wherein the water shield comprises a sheet of foam material.
4. The combined trim panel and water shield assembly of claim 1 , wherein the first and second predetermined patterns are the same.
5. The combined trim panel and water shield assembly of claim 1 , further comprising:
a protective sheet removably engaging the second adhesive layer.
6. The combined trim panel and water shield assembly of claim 5 , wherein the protective sheet comprises a release-treated plastic sheet.
7. The combined trim panel and water shield assembly of claim 1 , wherein the first and second adhesive layers are the same or different, and are selected from the group consisting of removable pressure-sensitive adhesives, permanent pressure-sensitive adhesives, and a compressible seal.
8. The combined trim panel and water shield assembly of claim 7 , wherein the first adhesive material is a permanent pressure-sensitive adhesive and the second adhesive material is a compressible seal.
9. The combined trim panel and water shield assembly of claim 7 , wherein the first adhesive material is a temporary pressure-sensitive adhesive and the second adhesive material is a permanent pressure-sensitive adhesive.
10. A method for the production of a combined water shield and trim panel structure, comprising:
providing a trim panel configured to cover a door panel, the trim panel having a first surface configured to face an interior compartment of a vehicle;
providing a generally flat sheet of material having opposite first and second surfaces and having a size and shape to generally conform to the trim panel and the door panel;
applying a first adhesive material to the first surface of the flat sheet in a first predetermined pattern;
applying a second adhesive material to the second surface of the flat sheet in a second predetermined pattern;
aligning the flat sheet and the trim panel so that the first surface of the flat sheet is in facing relation with a second surface of the trim panel, the second surface of the trim panel opposite the first surface thereof; and
contacting the trim panel with the first adhesive to attach the trim panel to the water shield.
11. The method of claim 10 , wherein the flat sheet comprises a sheet of flexible plastic material.
12. The method of claim 10 , wherein the flat sheet comprises a sheet of foam material.
13. The method of claim 10 , wherein the first and second predetermined patterns are the same.
14. The method of claim 10 , further comprising:
removably applying a protective sheet of material to the second adhesive layer.
15. The method of claim 14 , wherein the protective sheet comprises a release-treated plastic sheet.
16. The method of claim 10 , wherein the first and second adhesive layers are the same or different, and are selected from the group consisting of removable pressure-sensitive adhesives, permanent pressure-sensitive adhesives, and a compressible seal.
17. The method of claim 16 , wherein the first adhesive material is a permanent pressure-sensitive adhesive and the second adhesive material is a compressible seal.
18. The method of claim 16 , wherein the first adhesive material is a temporary pressure-sensitive adhesive and the second adhesive material is a permanent pressure-sensitive adhesive.
19. A sealing system for application to a vehicle inner door panel for preventing the entry of water or dust from entering an interior compartment of the vehicle, comprising:
a trim panel configured for covering the vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface; and
a sealing member engaging at least one of the trim panel and the vehicle door panel and providing a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.
20. The sealing system of claim 19 , wherein the sealing member comprises a compressible gasket engaging a peripheral edge of one of the vehicle door panel and the trim panel.
21. The sealing system of claim 20 , wherein said gasket does not completely circumscribe the peripheral edge.
22. The sealing system of claim 20 , wherein said gasket completely circumscribes the peripheral edge.
23. The sealing system of claim 20 , wherein the sealing member forms one or more bands and further comprising a second sealing member engaging one of the vehicle door panel and the trim panel within the one or more peripheral bands of the first sealing member.
24. The sealing system of claim 23 , wherein the second sealing member circumscribes one or both of an opening in the trim panel and an opening in the door panel.
25. The sealing system of claim 19 , wherein the sealing member is retained on the trim panel using one or more mechanical fasteners.
26. The sealing system of claim 19 , wherein the sealing member is attached to one of the vehicle door panel and the trim panel using an adhesive.
27. The sealing system of claim 19 , wherein the sealing member is attached to one of the vehicle door panel and the trim panel using a combination of adhesive and one or more mechanical fasteners.
28. The sealing system of claim 19 , further comprising:
a plurality of mechanical fasteners which engage the trim panel, the sealing member, and the door panel.
29. The sealing system of claim 19 , wherein the door panel comprises a generally flat portion which is aligned with and sealingly engages the sealing member when the trim panel is installed on the door panel.
30. The sealing system of claim 19 , wherein the trim panel comprises one or more pressure ribs engaging the sealing member.
31. The sealing system of claim 19 , wherein the sealing member comprises a compressible foam material.
32. The sealing system of claim 19 , wherein the sealing members is an adhesive.
33. The sealing system of claim 19 , wherein the sealing member is a removable pressure-sensitive adhesive.
34. The sealing system of claim 19 , wherein the sealing member is a generally permanent pressure-sensitive adhesive.
35. The sealing system of claim 19 , wherein the sealing member is compressible forming a compression-type gasket when the trim panel is attached to the vehicle door panel.
36. The sealing system of claim 19 , wherein the sealing member is a compressible formed-in-place gasket.
37. The sealing system of claim 19 , wherein the sealing member is a compressible water shield adapted to be disposed between the door panel and trim panel.
38. The sealing system of claim 19 , further comprising a water shield engaging the sealing member and adapted to be disposed between the door panel and trim panel.
39. The sealing system of claim 38 , wherein the water shield is compressible.
40. The sealing system of claim 39 , wherein the water shield is a foam material.
41. The sealing system of claim 40 , wherein the water shield is an open-cell foam material.
42. The sealing system of claim 40 , wherein the water shield is a closed-cell foam material.
43. The sealing system of claim 38 , wherein the water shield is non-compressible.
44. The sealing system of claim 43 , wherein the water shield is rigid.
45. The sealing system of claim 38 , wherein the water shield is a polymer film.
46. The sealing system of claim 19 , further comprising a release coated protective liner applied over the sealing member for removal prior to the installation of the trim panel to the vehicle door panel.
47. The sealing system of claim 19 , further comprising a second sealing member engaging the other of the trim panel and the vehicle door panel and providing a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.
48. The sealing system of claim 47 wherein the first and second sealing members are formed of the same material.
49. The sealing system of claim 47 wherein the first and second sealing members are formed of different materials.
50. A method for sealing a vehicle door interior trim panel against entry of water or dust, comprising:
attaching at least one compressible sealing member to a trim panel such that the at least one sealing member is positioned to provide a sealing interference between the door panel and the trim panel when the trim panel is installed on the door panel; and
installing the trim panel retaining the at least one compressible sealing member onto the door panel.
51. The method of claim 50 , wherein the sealing member is retained on the trim panel using one or more mechanical fasteners.
52. The method of claim 50 , wherein the sealing member is attached to the trim panel using an adhesive.
53. The method of claim 50 , wherein the sealing member is attached to the trim panel using a combination of adhesive and one or more mechanical fasteners.
54. The method of claim 50 , further comprising:
a plurality of mechanical fasteners which engage the trim panel, the one or more compressible sealing members, and the door panel.
55. A stacked plurality of sealing systems, each adapted for application to a vehicle door panel, comprising:
a first sealing system including (i) a first trim panel adapted to cover a vehicle door panel, said first trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite said first surface, and (ii) a first sealing member engaging said first trim panel and providing a sealing interference between said vehicle door panel and said first trim panel when the first trim panel is installed on the vehicle door panel;
a second sealing system positioned adjacent said first sealing system, said second sealing system including (i) a second trim panel adapted to cover a vehicle door panel, said second trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite said first surface, and (ii) a second sealing member engaging said second trim panel and providing a sealing interference between said vehicle door is panel and said second trim panel when the second trim panel is installed on the vehicle door panel; and
a releasable protective liner disposed between said first and said second sealing systems.
56. The stacked plurality of sealing systems of claim 55 further comprising:
an adhesive disposed on at least one of said first sealing member and said second sealing member, said adhesive contacting said protective liner.
57. A combined trim panel and water shield assembly for a vehicle comprising:
a trim panel adapted for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface;
a generally flat non-compressible water shield having opposite first and second surfaces and having a size and shape to generally conform to a surface of said trim panel and a surface of said vehicle door panel; and
an adhesive layer engaging the first surface of the flat sheet and the second surface of the trim panel, the first adhesive layer applied in a first predetermined pattern.
58. A combined trim panel and water shield assembly for a vehicle comprising:
a trim panel configured for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface;
a generally flat non-compressible water shield having opposite first and second surfaces and having a size and shape to generally conform to a surface of said trim panel and a surface of said vehicle door panel, said first surface of said flat sheet engaging said trim panel; and
an adhesive layer engaging the second surface of the flat sheet and applied in a predetermined pattern adapted to engage said vehicle door panel.
Priority Applications (1)
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US11/178,718 US20060012218A1 (en) | 2001-05-03 | 2005-07-11 | Sealing systems and related methods for automotive interior trim panels and the like |
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US10/137,542 US6991278B2 (en) | 2001-05-03 | 2002-05-02 | Sealing systems and related methods for automotive interior trim panels and the like |
US11/178,718 US20060012218A1 (en) | 2001-05-03 | 2005-07-11 | Sealing systems and related methods for automotive interior trim panels and the like |
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US10/137,542 Division US6991278B2 (en) | 2001-05-03 | 2002-05-02 | Sealing systems and related methods for automotive interior trim panels and the like |
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US11/178,718 Abandoned US20060012218A1 (en) | 2001-05-03 | 2005-07-11 | Sealing systems and related methods for automotive interior trim panels and the like |
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2002
- 2002-05-02 US US10/137,542 patent/US6991278B2/en not_active Expired - Fee Related
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2005
- 2005-07-11 US US11/178,718 patent/US20060012218A1/en not_active Abandoned
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US20090169860A1 (en) * | 2005-12-21 | 2009-07-02 | Takahashi Katsunori | Closed-Cell Foamed Rubber Sheet, Laminate, and Waterproof/Watertight Sealing Material Made of the Sheet or Laminate |
US20110099910A1 (en) * | 2006-10-18 | 2011-05-05 | Johnson Controls Technology Company | Vehicle door having a sealing plane and having a sealing element whose ends overlap |
US20120169083A1 (en) * | 2009-07-03 | 2012-07-05 | Nitto Denko Corporation | Door hole cover and vehicular door structure |
US8534738B2 (en) * | 2009-07-03 | 2013-09-17 | Nitto Denko Corporation | Door hole cover and vehicular door structure |
US20120299329A1 (en) * | 2009-09-09 | 2012-11-29 | Johnson Control Technology Company | Vehicle door arrangement and method for the assembly thereof |
US8944488B2 (en) * | 2009-09-09 | 2015-02-03 | Johnson Controls Technology Company | Vehicle door arrangement and method for the assembly thereof |
Also Published As
Publication number | Publication date |
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US6991278B2 (en) | 2006-01-31 |
US20030001408A1 (en) | 2003-01-02 |
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