Door outside belt for vehicle

Abstract

A hybrid-type door outside belt for a vehicle utilizes different materials for a skin layer of a skin body that is mounted to an upper end of a door panel and a main wing that is moved by contacting the door glass, the skin layer of the skin body being made of a material having excellent scratch-resistance, and the main wing being made of a material having excellent compression set (deformation).

Claims

1. A door outside belt for a vehicle, the door outside belt comprising: a core plate providing a frame of the door outside belt; a polyvinyl chloride (PVC) skin layer provided by being extruded over an inner surface and an outer surface of the core plate; a PVC auxiliary wing provided by being integrally molded on an inside upper end of the PVC skin layer; and a thermoplastic vulcanizate (TPV) main wing provided by being extruded on a partial section of an inside outer surface of the core plate, wherein a PVC adhesive is applied to the inner surface and the outer surface of the core plate, and a TPV adhesive is applied to the partial section of the inside outer surface of the core plate, wherein the PVC adhesive and the TPV adhesive which are applied to the inside outer surface of the core plate are applied with approximately a 1-3 mm buffer section between the adhesives so as to prevent the adhesives from being mixed together.

2. The door outside belt of claim 1, wherein the core plate comprises: a connection end that is inserted into an inside of a door panel and has a vertically standing shape; an outer molding end that is bent outward from an upper end portion of the connection end; and an outer supporting end that is bent inward from a lower end portion of the outer molding end, wherein a bent portion between the connection end and the outer molding end and a bent portion between the outer molding end and the outer supporting end are formed with a radius of curvature (R) ranging from approximately 1-30 mm.

3. The door outside belt of claim 2, wherein the PVC skin layer is provided by being extruded on an entire surface of the connection end except for a part between an upper end and a lower end of an inside outer surface thereof, on an inner surface and an outer surface of the outer molding end, and on an outer surface of the outer supporting end.

4. The door outside belt of claim 3, wherein a PVC adhesive is applied to the entire surface of the connection end except for the part between the upper end and the lower end of the inside outer surface thereof, to the inner surface and the outer surface of the outer molding end, and to the outer surface of the outer supporting end, and then the PVC skin layer is extruded thereon.

5. The door outside belt of claim 2, wherein, on a part between an upper end and a lower end of an inside outer surface of the connection end, the TPV main wing is provided by being extruded.

6. The door outside belt of claim 5, wherein a TPV adhesive is applied to the part between the upper end and the lower end of the inside outer surface of the connection end with approximately 1-3 mm buffer sections between upper and lower PVC skin layers, and then the TPV main wing is attached thereon when the TPV main wing is provided by being extruded.

7. The door outside belt of claim 1, wherein, when the TPV main wing is provided by being extruded, an end of the TPV main wing that is in contact with the PVC auxiliary wing is provided to have higher hardness (Hs) than another portion of the TPV main wing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other objects, features and other advantages of the present disclosure will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which.

(2) FIG. 1 (RELATED ART) is a schematic view showing a location of a door outside belt apparatus of a vehicle.

(3) FIG. 2 (RELATED ART) is a sectional view showing a structure of a conventional door outside belt taken along A-A line of FIG. 1.

(4) FIG. 3 (RELATED ART) is a schematic flow diagram showing a method for manufacturing the conventional door outside belt.

(5) FIG. 4 is a schematic flow diagram showing a method for manufacturing a door outside belt according to the present disclosure.

(6) FIG. 5 is a sectional view showing a structure and a mounting state of the door outside belt according to the present disclosure.

(7) FIG. 6 is a view showing comparison between scratch test results of the conventional door outside belt and the door outside belt of the present disclosure.

(8) FIG. 7 is a view showing comparison between colors of the conventional door outside belt and the door outside belt of the present disclosure.

DETAILED DESCRIPTION

(9) It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a vanety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g., fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example both gasoline-powered and electric-powered vehicles.

(10) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Throughout the specification, unless explicitly described to the contray, the word “comprise” and variations such as “comprises” or “comprising” will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. In addition, the terms “unit”, “-er”, “-or”, and “module” described in the specification mean units for processing at least one function and operation, and can be implemented by hardware components or software components and combinations thereof.

(11) Further, the control logic of the present disclosure may be embodied as non-transitory computer readable media on a computer readable medium containing executable program instructions executed by a processor, controller or the like. Examples of computer readable media include, but are not limited to, ROM, RAM, compact disc (CD)-ROMs, magnetic tapes, floppy disks, flash drives, smart cards and optical data storage devices. The computer readable medium can also be distributed in network coupled computer systems so that the computer readable media is stored and executed in a distributed fashion, e.g., by a telematics server or a Controller Area Network (CAN).

(12) Hereinbelow, an exemplary embodiment of the present disclosure will be described in detail with reference to the accompanying drawings.

(13) FIG. 4 is a schematic flow diagram showing a method for manufacturing a door outside belt according to the present disclosure. FIG. 5 is a sectional view showing a structure and a mounting state of the door outside belt according to the present disclosure.

(14) After a core plate is uncoiled from a roll around which a core plate 112 made of stainless steel (SUS) or aluminum (AL) is coiled, two types of adhesives are applied to an inner surface and an outer surface of the core plate 112, respectively.

(15) That is, when the core plate 112 is fed into a roll-forming machine and then formed in a predetermined sectional form before the two types of adhesives are applied thereto, there is a problem that an adhesive is not evenly applied to a bent portion of the core plate 112 that is generated during roll-forming. Accordingly, it is preferable that the two types of adhesives are applied to the core plate 112 when the core plate 112 is in a flat state by being uncoiled from the roll.

(16) Therefore, an adhesive applying process proceeds such that a polyvinyl chloride (PVC) adhesive 130 is applied to a first surface of the core plate 112, and simultaneously, the PVC adhesive 130 and a thermoplastic vulcanizate (TPV) adhesive 132 are applied to a second surface thereof with an interval between the adhesives.

(17) A polar acrylic adhesive is used as the PVC adhesive 130 for smooth adhesion between a PVC structure and a SUS or AL metallic material. A non-polar olefin adhesive is used as the TPV adhesive 132 for smooth adhesion between a TPV structure and the SUS or AL metallic material. Preferably, the PVC adhesive 130 and the TPV adhesive 132 are disposed so as not to overlap or be mixed together.

(18) For the reasons provided above, the PVC adhesive 130 and the TPV adhesive 132 are applied to the second surface of the core plate 112 with approximately 1-3 mm buffer sections between the adhesives so as to prevent the adhesives from being mixed together, as shown in FIG. 4.

(19) Next, the flat-plate core plate 112 to which the PVC adhesive 130 and the TPV adhesive 132 are applied is fed into the roll-forming machine and formed in a shape which forms a frame of the door outside belt.

(20) In a forming process by the roll-forming machine, the core plate 112 is formed to have a connection end 112-1, and outer molding end 112-2, and an outer supporting end 112-3. The connection end 112-1 has a vertically standing shape, the outer molding end 112-2 is bent outward from an upper end portion of the connection end 112-1, and the outer supporting end 112-3 is bent inward from a lower end portion of the outer molding end 112-2. Especially, a bent portion 112-4 between the connection end 112-1 and the outer molding end 112-2 and a bent portion 112-5 between the outer molding end 112-2 and the outer supporting end 112-3 are formed with a radius of curvature R greater than or equal to 1 mm, preferably, with a radius of curvature R ranging from approximately 1-30 mm.

(21) Reasons for forming the bent portions 112-4 and 112-5 with the radius of curvature R ranging from approximately 1-30 mm are as follows. One reason is to smoothly mount the door outside belt having the core plate 112 as an inner frame to an upper end of the door panel depending on the vehicle type, because vehicles have a variety of shapes of door panels depending on vehicle types. Another reason is to prevent the PVC adhesive 130 from being removed from outer surfaces of the bent portions 112-4 and 112-5, where removing of the PVC adhesive occurs due to stress concentrated on the bent portions 112-4 and 112-5 during the forming process.

(22) That is, when the bent portions 112-4 and 112-5 are bent with a radius of curvature R less than 1 mm, the PVC adhesive 130 applied to the outer surfaces of the bent portions 112-4 and 112-5 is removed from the surfaces easily due to the stress concentrated on the bent portions 112-4 and 112-5. However, when the bent portions 112-4 and 112-5 are formed with the radius of curvature R greater than or equal to 1 mm, it is possible to minimize or prevent the removing of the PVC adhesive 130. Therefore, it is preferable that the bent portions 112-4 and 112-5 are formed with the radius of curvature R greater than or equal to 1 mm, and more preferably, the bent portions 112-4 and 112-5 are formed with the radius of curvature R ranging from approximately 1-30 mm for accommodating various door structures and door shapes for vehicle types.

(23) Next, an extrusion process proceeds. In this process, a PVC skin layer 140 and a PVC auxiliary wing 142 are extruded on a surface, where the PVC adhesive 130 is applied, of the core plate 112 formed as described above. Simultaneously, a PTV main wing 120 is extruded on an area where the TPV adhesive 132 is applied by using a known extruding device.

(24) For example, when the core plate 112 formed as described above passes through the extruding device, PVC resin is extruded from a PVC supply nozzle provided in a location of the extruding device to the surface of the core plate 112 where the PVC adhesive 130 is applied. Simultaneously, TPV resin is extruded from a TPV supply nozzle provided in another location of the extruding device to the area of the core plate 112 where the TPV adhesive 132 is applied. Accordingly, the PVC skin layer 140 and the PVC auxiliary wing 142 can be extruded on the surface of the core plate 112 where the PVC adhesive 130 is applied, and the PTV main wing 120 can be extruded on the area where the TPV adhesive 132 is applied.

(25) Particularly, the PVC adhesive 130 and the TPV adhesive 132 are applied to the core plate 112 before the above-described forming process. For the reasons provided above, even when the core plate 112 is formed to have the connection end 112-1 having the vertically standing shape, the outer molding end 112-2 bent outward from the upper end portion of the connection end 112-1, and the outer supporting end 112-3 bent inward from a lower end portion of the outer molding end 112-2 by the forming process, the PVC adhesive 130 is applied to the entire inner and outer surfaces of the outer molding end 112-3 and the outer supporting end 112-3, and the PVC adhesive 130 is also applied to an entire inner surface of the connection end 120-1 and upper and lower ends of the outer surface thereof.

(26) In addition, the TPV adhesive 132 is applied to a partial section between the upper and lower ends of the outer surface of the connection end 112-1 with 1-3 mm buffer sections between upper and lower PVC adhesives 130.

(27) Therefore, in the extrusion process, the PVC skin layer 140 and the PVC auxiliary wing 142 are integrally extruded over the inner and outer surfaces of the outer molding end 112-2 and the outer supporting end 112-3 to which the PVC adhesive 130 is applied, the entire inner surface of the connection end 112-1, and the upper and lower ends of the outer surface of the connection end 112-1.

(28) In addition, in the extrusion process, the soft PTV main wing 120 is integrally extruded over the part between the upper and lower ends of the outer surface of the connection end 112-1, that is, a surface with the TPV adhesive 132.

(29) Meanwhile, an optimal extrusion molding temperature of PVC resin when the PVC resin forming the PVC skin layer 140 and the PVC auxiliary wing 142 is extruded from the extruding device is a temperature ranging from approximately 110° C.-175° C., and an optimal extrusion molding temperature of TPV resin when the TPV resin forming the main wing is extruded from the extruding device is a temperature ranging from approximately 165° C.-210° C. In view of this, the PVC skin layer 140 and the PVC auxiliary wing 142 in addition to the main wing 120 are extruded at a temperature ranging from approximately 165° C.-170° C. at which the PVC resin and the TPV resin can be extruded simultaneously.

(30) According to a method for manufacturing the door outside belt of the present disclosure as described above, the door outside belt manufactured by the method includes the core plate 112 forming the frame of the door outside belt, the PVC skin layer 140 extruded over the inner surface and the outer surface of the core plate 112, the PVC auxiliary wing 142 integrally molded on the inside upper end of the PVC skin layer 140, and the PTV main wing 120 extruded on the partial section of the inside outer surface of the core plate 112.

(31) In particular, as shown in FIG. 5, the door outside belt of the present disclosure manufactured by the above-described method includes: the metal core plate 112 forming the frame of the door outside belt; the PVC skin layer 140 that is extruded on the entire inner surface of the connection end 112-1 and the upper and lower ends of the outer surface thereof, in addition to the entire inner and outer surfaces of the outer molding end 112-2 and the outer supporting end 112-3 provided in the core plate 112; the PVC auxiliary wing 142 that is integrally molded on the inside upper end of the PVC skin layer 140; and the soft TPV main wing 120 that is extruded on the surface between the upper and lower ends of the outer surface of the connection end 112-1.

(32) The door outside belt of the present disclosure manufactured as described above is mounted on an upper end of the door panel 10, as shown in FIG. 5.

(33) That is, as the upper end of the door panel 10 is fitted into an inside between the connection end 112-1 and the outer molding end 112-2 of the core plate 112, the door outside belt of the present disclosure is fixed on the upper end of the door panel 10.

(34) Simultaneously, the main wing 120 is in close contact with a surface of a door glass 20 so as to be vertically movable.

(35) In particular, the connection end 112-1 of the core plate 112 is inserted into an inside of the door panel 10 and then the outer molding end 112-2 and the outer supporting end 112-3 are located at the outside the door panel 10. Therefore, outer surfaces of the PVC skin layer 140 and the PVC auxiliary wing 142 are exposed to the outside of the door panel 10. In addition, the PTV main wing 120 is in close contact with the surface of the door glass 20 so as to be vertically movable.

(36) As shown in FIG. 5, with up and down movement of the door glass 20, the PTV main wing 120 is folded and then contacts the PVC auxiliary wing 142 formed of a different material from the PTV main wing 120. Thus, friction connection may be generated therein.

(37) To solve this problem, when the PTV main wing 120 is extruded from the known extruding device, an end of the PTV main wing 120 (that is a part contacting with the PVC auxiliary wing 142) is extruded to have greater hardness (Hs) than another part of the main wing 120. Therefore, when the end of the PTV main wing 120 contacts with the PVC auxiliary wing 142 in which the different material is used, the PTV main wing 120 is induced to slidingly contact the PVC auxiliary wing 142 without friction. Accordingly, fiction connection can be easily prevented.

(38) The PTV main wing 120 is in close contact with the surface of the door glass 20 so as to be vertically movable and perform a sealing function for preventing dust and foreign material from being penetrated into the door panel. Outer surfaces of the PVC skin layer 140 and the PVC auxiliary wing 142 are exposed to the outside and function as molding lines and gamishes.

(39) In addition, when the main wing 120 is tiled upward by being in close contact with the door glass 20, the main wing 120 is in closed contact with an inside portion of the PVC auxiliary wing 142. Here, the PVC auxiliary wing 142 also performs the sealing function with the main wing 120 for preventing dust and foreign material penetrating the door panel.

(40) According to the present disclosure, the PVC skin layer 140 and the PVC auxiliary wing 142 of the door outside belt are an extruded PVC material that has excellent scratch-resistance as compared to a hard TPV material. Thus, the outer surfaces of the PVC skin layer 140 and the PVC auxiliary wing 142 exposed to the outside of the door panel can be maintained in a clean state without scratches, as shown in a right drawing of FIG. 6.

(41) In addition, the PVC skin layer 140 and the PVC auxiliary wing 142 are the same extruded PVC material. Therefore, unlike a conventional case in which a second skin layer and an auxiliary wing make a boundary line and are different colors due to being formed of different materials, the PVC skin layer 140 and the PVC auxiliary wing 142 are the same color, as shown in a right drawing of FIG. 7. Accordingly, the door outside belt of the present disclosure has advanced satisfactory appearance as compared to the conventional door outside belt.

(42) Although a preferred embodiment of the present disclosure has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the disclosure as disclosed in the accompanying claims.