Carrier Having A Living Hinge

[0001] 1. Field of the Invention

[0002] The subject invention generally relates to a weatherstrip assembly for a motor vehicle and more specifically to the manner in which the weatherstrip assembly attaches to the motor vehicle.

[0003] 2. Description of Related Art

[0004] Various weatherstrip assemblies for motor vehicle are known in the art. For example, a weatherstrip assembly can have a carrier with a generally U-shaped configuration for mounting to a motor vehicle. The carrier typically includes a tab for preventing the carrier from detaching from the motor vehicle. A hinge is disposed between the carrier and the tab for allowing flexibility during fastening of the tab to the motor vehicle. The hinge has a uniform thickness across an entire width of the hinge. The uniform thickness of the hinge is less than a thickness of the tab or u-shaped configuration of the carrier. In other words, the uniform thickness across the entire width of the hinge is thin to facilitate movement of the tab. However, the durability of the hinge can be an issue in certain applications.

[0005] Therefore, there remains an opportunity to provide a weatherstrip assembly including a living hinge having adequate flexibility, but improved durability.

[0006] The invention provides a weatherstrip assembly for a motor vehicle. The weatherstrip assembly includes a carrier having a base. The carrier has a first leg extending away from the base to a first distal end. The weatherstrip assembly has a seal mounted to the first distal end of the first leg of the carrier. The carrier also has a second leg extending away from the base to a second distal end. The first and second legs are spaced from each other to define a channel. At least one securing flange is coupled to the second distal end of the second leg for fastening the carrier to the motor vehicle. The weatherstrip assembly has a living hinge disposed between the securing flange and the second distal end of the second leg, such that the securing flange is moveable independent of the carrier. The living hinge has a first edge and a second edge that oppose each other. The living hinge has a first portion defining a first thickness and a second portion defining a second thickness greater than the first thickness for improving durability of the living hinge.

[0007] One advantage of the present invention is the second thickness of the second portion of the living hinge is greater than the first thickness of the first portion for exceeding previous durability levels and extending the useful life of the living hinge. Another advantage is the first thickness of the first portion of the living hinge is less than the second thickness of the second portion of the living hinge for increasing flexibility of the living hinge. Increased flexibility is useful during fastening of the securing flange to the motor vehicle. Therefore, balancing the first thickness and the second thickness improves durability and flexibility of the living hinge, which improves the useful life of the weatherstrip assembly.

[0018] Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a weatherstrip assembly 10 for a motor vehicle 12 is generally illustrated in FIGS. 1-4. The motor vehicle 12 has a front door 14 and a rear door 16 adjacent to each other. In certain applications, the weatherstrip assembly 10 is coupled with the rear door 16. However, it has been contemplated that the weatherstrip assembly 10 of the subject invention can be coupled to the front door 14 or any suitable location as needed in other applications.

[0019] Referring also to FIGS. 5 and 6, when the front door 14 and the rear door 16 are in the closed position, a void is present between a rear end 18 of the front door 14 and a front end 20 of the rear door 16. The weatherstrip assembly 10 of the present invention fills the void between the rear end of the front door 14 and the front end of the rear door 16, as illustrated in FIGS. 1 and 2.

[0020] The weatherstrip assembly 10 includes a carrier 22 having a base 24. The carrier 22 has a first leg 26 extending from the base 24 to a first distal end 28. The weatherstrip assembly 10 also includes a seal 86 mounted to the carrier 22. More specifically, the seal 86 is coupled to the first distal end 28 of the first leg 26. The seal 86 is visible from outside the motor vehicle 12 filling the void between the front door 14 and the rear door 16. The seal 86 engages the front door 14, when the front door 14 is in the closed position, for sealing the front door 14 and the rear door 16 of the motor vehicle 12.

[0021] The seal 86 is typically black in color, so that the seal 86 can function unnoticed. However, the seal 86 could be any color to either match or contrast with the color of the motor vehicle 12. The seal 86 is typically made of a polymeric material. More specifically, the seal 86 is an elastomeric material. Although, the polymeric material may be further defined in other embodiments as a thermoplastic material, an elastomeric material, and/or any other suitable polymeric material.

[0022] The carrier 22 also has a second leg 36 extending away from the base 24 to a second distal end 38. At least a portion of the first leg 26 and the second leg 36 are substantially parallel to each other and are spaced from each other to define a channel 40, as illustrated in FIGS. 3-7. The channel 40 of the carrier 22 receives the door for mounting the weather assembly thereon, as best illustrated in FIGS. 5 and 6.

[0023] The carrier 22 has at least one securing flange 44 coupled to the second distal end 38 of the second leg 36. More specifically, the at least one securing flange 44 is further defined as a plurality of securing flanges 46, as shown in FIGS. 2, 3, and 4. The securing flange 44 is used for fastening the carrier 22 to the motor vehicle 12 and will be described in greater detail below.

[0024] Referring also to FIGS. 7-9, the carrier 22 has a living hinge 48. It is to be appreciated that the carrier 22 having the plurality of securing flanges 44, will also have a plurality of living hinges 50, as illustrated in FIG. 4. The living hinge 48 is disposed between the securing flange 44 and the second distal end 38 of the second leg 36. The living hinge 48 allows the securing flange 44 to move independent of the carrier 22. Movement of the securing flange 44 occurs between an unattached position shown in FIG. 5, and an attached position shown in FIG. 6. The living hinge 48 has a first edge 52 and a second edge 54. As shown in FIG. 8, the first edge 52 and the second edge 54 are opposing each other. As such, the first edge 52 and second edge 54 are further defined as a boundary for the living hinge 48.

[0025] As best seen in FIGS. 8 and 9, the living hinge 48 has a first portion 56 and a second portion 58. The first portion 56 defines a first thickness T1 and the second portion 58 defines a second thickness T2 greater than the first thickness T1 for improving durability of the living hinge 48. Likewise, the first thickness T1 is less than the second thickness T2 for improving the flexibility of the living hinge 48. The concept of improving flexibility is described further below.

[0026] The living hinge 48 has a width W extending between the edges. More specifically, the first portion 56 extends along a first section S1 of the width W and the second portion 58 extends along a second section S2 of the width W. In the preferred embodiment, the second section S2 is defined as being less than the first section S1. The second section S2 is further defined as being less than 50% of the width W. In the most preferred embodiment, the first section S1 is 13.35 mm wide and the second section S2 is 1.76 mm wide.

[0027] The second portion 58 is disposed between the first edge 52 and the first portion 56. More specifically, the second portion 58 includes a first segment 60 disposed between the first edge 52 and the first portion 56 and a second segment 62 disposed between the second edge 54 and the first portion 56. The first segment 60 of the second portion 58 extends along the second section S2 of the width W. The second segment 62 of the second portion 58 extends along a third section S3 of the width W. As discussed above, the first section S1 is most preferably 13.35 mm wide and the second section S2 is most preferably 1.76 mm wide. In one embodiment, the third section S3 has a width equal to the second section S2, i.e. 1.76 mm wide. A sum of the first, second, and third sections preferably equal the entire width W. As such, the width W preferably equals 16.87 mm. In a preferred embodiment, a sum of said second and third sections of the width W is less than the first section S1 of the width W. However, it is to be appreciated that other embodiments of the hinge may include more or less portions having varying widths and thicknesses of those portions.

[0028] The first portion 56 has a first length L1 extending transverse to the width W. The second portion 58 has a second length L2 also extending transverse to the width W. The second length L2 is equal to the first length L1, in the preferred embodiment, each of the first length L1 and second length L2 are less than the width W of the living hinge 48.

[0029] As best shown in FIG. 9, the living hinge 48 has a first front side 64 and a first back side 66 opposing the first front side 64. The first portion 56 defines a recess 68 in the first front side 64 which extends toward the first back side 66. Therefore, the recess 68 represents a lack of material in the first portion 56 resulting in the first thickness T1 being less than the second thickness T2 of the second portion 58, thereby increasing flexibility of the living hinge 48. In one alternative, the recess 68 may extend from the first back side 66 toward the first front side 64. In another alternative, a recess 68 may extend from both the first front side 64 and the first back side 66 thereby defining a pair of opposing recesses.

[0030] The securing flange 44 defines an aperture 70 for receiving a fastener 72 to secure the carrier 22 to the motor vehicle 12. In the present invention the securing flange 44 is fastened to the rear door 16 of the motor vehicle 12, as seen in FIGS. 2 and 6. The aperture 70 is generally circular in configuration. Alternatively, it has been contemplated that the aperture 70 may be oval in configuration or any other suitable configuration. In another embodiment, the fastener 72 may be molded to or integrated formed with the securing flange 44 during molding of the carrier 22.

[0031] The securing flange 44 further includes a second front side 74 and a second back side 76 opposing each other. The securing flange 44 also defines a depression 78 extending inwardly from the second front side 74 to the second back side 76. The securing flange 44 further defines a protrusion 80 extending outwardly away from the second back side 76 such that the protrusion 80 aligns with the depression 78. The protrusion 80 also defines the aperture 70 extending through. In other words, the aperture 70 extends through the securing flange 44 and the protrusion 80. The depression 78 and the protrusion 80 allow for reinforcing the aperture 70 while fastening the securing flange 44 of the carrier 22 to the motor vehicle 12.

[0032] The second leg 36 defines at least one slot 42. The slot 42 is adjacent to the first edge 52 of the living hinge 48. As illustrated in FIGS. 7 and 8, the slot 42 is further defined as a first slot 82 adjacent to the first edge 52 and further includes a second slot 84 adjacent to the second edge 54 of the living hinge 48. The slots 42 allow additional movement of the second leg 36 independent of the carrier 22 for improving durability during installation.

[0033] The carrier 22 is formed of a rigid material, which enables the carrier 22 to retain its shape. As such, the rigid material enables the legs of the carrier 22 to retain their shape, such that the channel 40 is able to receive the rear door 16 for mounting the weather assembly. The securing flange 44, the living hinge 48, the second leg 36 are integrally formed of a polymeric material. More specifically, the first leg 26, the second leg 36, the base 24, the securing flange 44, and the living hinge 48 are integrally formed of the polymeric material. In one embodiment, the polymeric material is further defined as a nylon-reinforced polyproplene. For example, the polymeric material for the first leg 26, the second leg 36, the base 24, the securing flange 44, and the living hinge 48 can be further defined as the nylon-reinforced polyproplene, such as talc. Of course, the polymeric material could be made of materials other than the nylon-reinforced polyproplene. It is to be appreciated that the first portion 56 and the second portion 58 of the living hinge 48 may be formed having metals, glass, organic binders or any other materials to yield properties suitable for the weatherstrip assembly 10 of this invention.

[0034] It is to be understood that the terminology which has been used herein is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above description and teachings. The invention may be practiced otherwise than as specifically described within the scope of the appended claims. Additionally, although the Figures are not necessarily to scale, it is be understood that the Figures do accurately represent relative ratios in the size and dimensions between the various discrete components of the weatherstrip assembly of this invention.