CROSS REFERENCE TO RELATED APPLICATION

[0001] The subject application claims priority to and all the benefits of U.S. Provisional Application No. 62/466,733, filed on March 3, 2017, the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to a seal assembly for a vehicle.

BACKGROUND

[0003] Seal assemblies are often disposed between fixed and/or movable window closure members attached, for example, to a door frame of a vehicle to form a seal at an interface between a window closure member and the door frame. The seal assembly includes a seal body typically formed from an elastomeric material (such as an ethylene propylene diene monomer (EPDM) rubber and/or a thermoplastic vulcanizate (TPV)). A decorative trim member or show piece may be coupled to an exposed surface of the seal body to improve the aesthetics of the exposed surface.

SUMMARY

[0004] A seal assembly for a vehicle is disclosed. The seal assembly comprises a seal body formed from an elastomer selected from an ethylene propylene diene monomer (EPDM) rubber, a thermoplastic vulcanizate (TPV), and combinations thereof. The seal assembly further comprises a decorative trim member coupled to the elastomeric seal body and formed from a polyvinyl chloride (PVC) material, a tie layer formed from a metal and having first and second sides with the metal tie layer disposed between the elastomeric seal body and said decorative trim member such that said first side faces said elastomeric seal body and said second side faces said PVC decorative trim member, an elastomer-to-metal adhesive disposed between the elastomeric seal body and the first side of the metal tie layer to bond the metal tie layer to the elastomeric seal body, and a PVC -to-metal adhesive disposed between the PVC decorative trim member and the second side of the metal tie layer to bond the PVC decorative trim member to the metal tie layer to couple the PVC decorative trim member to the elastomeric seal body, with the PVC -to-metal adhesive being different from the elastomer-to-metal adhesive. [0005] A method of forming a seal assembly is also disclosed. The seal assembly has a seal body formed from an elastomer selected from an ethylene propylene diene monomer (EPDM) rubber, a thermoplastic vulcanizate (TPV), and combinations thereof, and the seal assembly having a decorative trim member coupled to the seal body and formed from a polyvinyl chloride (PVC) material. The method comprises the steps of extruding the elastomer to form the seal body having a trim region and a plurality of locking cavities along the trim region, and molding the PVC material over the trim region of the seal body such that the PVC material flows into the locking cavities to mechanically interlock the decorative trim member with the seal body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. It is to be understood that the drawings are purely illustrative and are not necessarily drawn to scale.

[0007] Figure 1 is a side view of a rear door of a vehicle including a door frame with embodiments of a seal assembly coupled to the door frame.

[0008] Figure 2 is a semi -schematic, cross-sectional view of a portion of the door frame and a seal assembly according to one embodiment of the present disclosure.

[0009] Figure 3 is an enlarged segment of the cross-sectional view of the door frame and the seal assembly of Figure 2.

[0010] Figure 4 is an enlarged segment of the enlarged segment of Figure 3. Notably, the respective thicknesses of the adhesives 160, 162 are greatly exaggerated and not drawn to scale.

[0011] Figure 5 is a semi-schematic, cross-sectional view of a seal assembly and a fixed window closure member according to another embodiment of the present disclosure.

[0012] Figure 5 A is an exploded view of Figure 5.

[0013] Figure 6 is an enlarged segment of the cross-sectional view of the seal assembly of Figure 5. Notably, the respective thicknesses of the adhesives 260, 262 are greatly exaggerated and not drawn to scale.

[0014] Figure 7 is a semi-schematic, cross-sectional view of a seal assembly and a fixed window closure member according to yet another embodiment of the present disclosure.

[0015] Figure 7A is an exploded view of Figure 7. DETAILED DESCRIPTION

[0016] Referring now to the figures, wherein like numerals indicate corresponding parts throughout the several views, embodiments of a seal assembly 100, 200, 300 are shown throughout the figures and described in detail below. Figure 1 depicts a driver-side rear door 12 of a vehicle 10. The door 12 has a door frame 14 defining at least one window 16. The door 12 has a movable window closure member 18 (such as a glass window pane) movable between open and closed positions relative to the door frame 14. The movable window closure member 18 includes edges 20, and the edges 20 are received within the seal assembly 100, 200, 300, which is coupled to and extends along at least a portion of the door frame 14. The door 12 also has a fixed window closure member 22 (such as another glass window pane) supported by the door frame 14. The seal assembly 200, 300 divides or separates the fixed 22 and movable 18 window closure members.

[0017] Details of the seal assembly 100, 200, 300 are described below with reference to Figures 2-7 A. The seal assembly 100, 200, 300 includes a seal body 102, 202, 302 defining a longitudinal axis A. The longitudinal axis A may be nonlinear in instances where the seal body 102, 202, 302 bends or flexes to follow the contour of the door frame 14.

[0018] The seal body 102, 202, 302 of the seal assembly 100, 200, 300 is formed from an elastomer or elastomeric material selected from ethylene propylene diene monomer (EPDM) rubber, a thermoplastic vulcanizate (TPV), and combinations thereof. Thermoplastic vulcanizates are thermoplastic elastomers (TPE) having both thermoplastic and elastomeric properties. TPVs are often characterized as having a polyolefinic matrix, such as a polypropylene matrix, with an elastomer distributed within the matrix. The elastomer may be a cross-linked olefin copolymer elastomer (OCE), such as an elastomer formed from EPDM. In TPVs including EPDM, the diene is typically non-conjugated, non-limiting examples of which include dicyclopentiadiene, alkyldicyclopentadiene, 1,4-pentadiene, 1,4-hexadiene, 1,5- hexadiene, 1,4-heptadiene, 2-methyl-l,5-hexadiene, cyclooctadiene, 1,4-octadiene, 1,7- octadiene, 5-ethylidene-2-norbornene, 5-n-propylidene-2-norbornene, 5-butylidene-2- norbornene, and/or the like.

[0019] In an example, the TPV of the seal body 102 may be selected from an extrusion-grade TPV, non-limiting examples of which include TPVs of the SANTOPRE E® 121, 201, 691, 8291, and 9101 families available from Exxon-Mobil Corporation (Irving, TX). In another example, the TPV may be selected from any suitable TPV that is considered both an extrusion- grade TPV and a molding-grade TPV, non-limiting examples of which include various TPVs of the GEOLAST® 701 and 703 families and various TPVs of the SANTOPRE E® 101, 103, 121, 123, 201, 203, 241, 251, 291, 8191, 8201, and 8211, all of which are available from ExxonMobil Corporation (Irving, TX).

[0020] Ethylene propylene diene monomer (EPDM) rubber is an ethylene-alpha-olefin-non- conjugated diene rubber (EODM). The diene in the EPDM is non-conjugated, non-limiting examples of which include dicyclopentiadiene, alkyldicyclopentadiene, 1,4-pentadiene, 1,4- hexadiene, 1,5-hexadiene, 1,4-heptadiene, 2-methyl-l,5-hexadiene, cyclooctadiene, 1,4- octadiene, 1,7-octadiene, 5-ethylidene-2-norbornene, 5-n-propylidene-2-norbornene, 5- butylidene-2-norbornene, etc.

[0021] In an embodiment, the TPV and/or the EPDM may include one or more additives, such as vulcanization agents, lubricants, plasticizers, fillers, slip agents, processing oils, and/or various other components or additives. It should be appreciated that the seal body 102, 202, 302 could be formed from other elastomeric material(s), non-limiting examples of which include styrenebutadiene rubber (SBR), acrylonitrilebutadiene rubber, natural or synthetic isoprene rubber, chloroprene rubber, or other suitable elastomers known in the art.

[0022] Details of the seal assembly 100, according to one embodiment of the present disclosure, is described below with reference to Figures 2-4. The seal body 102 of the seal assembly 100 has a closed end 104 and an open end 106 opposite the closed end 104. The seal body 102 further has first 108 and second 110 limbs extending from the closed end 104 with the closed end 104, the first limb 108, and the second limb 110 defining interior 112 and exterior 114 surfaces of the seal body 102. The first 108 and second 110 limbs extend from the closed end 104 toward the open end 106. Additionally, the first 108 and second 110 limbs are spaced from one another, and the limbs 108, 110 extend substantially parallel to one another. In addition, the first 108 and second 110 limbs are transverse to the closed end 104. The closed end 104, the first limb 108, and the second limb 110 of the body 102 define a first channel 116 for receiving at least the edges 20 of the movable window closure member 18. In the illustrated embodiment, the first channel 116 is substantially 'U' shaped and extends along the longitudinal axis A. Notably, the shape of the first channel 116 is shown generically and/or schematically, and the 'U' shape of the first channel 116 may not necessarily be a perfectly shaped 'U'. Alternatively, the first channel 116 could have any suitable shape and/or configuration.

[0023] The seal body 102 further includes a plurality of sealing lips or fingers. In the present embodiment, the seal body 102 includes a first sealing lip 118, a second sealing lip 120, and a third sealing lip 122 extending from the interior surface 112 toward the first channel 116. The first 118 and second 120 sealing lips extend from the second limb 110 of the seal body 102, and the third sealing lip 122 extends from the first limb 108 of the seal body 102. The first 118 and second 120 sealing lips are spaced from one another. Additionally, the second sealing lip 120 (again which extends from the second limb 110) and the third sealing lip 122 (again which extends from the first limb 108) extend toward one another. The first 118, second 120, and third 122 sealing lips can move or flex to allow at least the edges 20 of the movable window closure member 18 to be received in the first channel 1 16. The first 118, second 120, and third 122 sealing lips are biased toward the first channel 116 to form a seal between the movable window closure member 18 and the door frame 14 when the movable window closure member 18 is received within the first channel 116.

[0024] The seal body 102 further has first 124 and second 126 tabs extending outwardly from the closed end 104. As shown in Figures 2 and 3, the first tab 124 extends from the closed end 104 adjacent the first limb 108. As shown in Figure 2, the second tab 126 extends from the closed end 104 adjacent the second limb 110. The first 124 and second tabs 126 are configured to engage the door frame 14 for coupling the seal assembly 100 to the door frame 14 when the seal assembly 100 is installed on the door frame 14.

[0025] Although not specifically shown in Figures 2-4, the seal assembly 100 may further include a metal carrier disposed in the seal body 102. In one configuration, the metal carrier is embedded in the seal body 102 and extends at least partially along a length of the seal body 102. The metal of the metal carrier may be chosen from any metal that will suitably provide rigidity and/or stability to the seal body 102. Non-limiting examples of suitable metals for the metal carrier include iron alloys (such as carbon steel, stainless steel, coated steel, electro-galvanized steel, mild steel, tool steel, etc.) and aluminum alloys.

[0026] As previously mentioned, the seal assembly 100 forms a seal between the movable window closure member 18 and the door frame 14 defined in the vehicle door 12. Typically, a portion of the seal assembly 100 is visible to the exterior of the vehicle 10 and becomes part of the outer decor of the vehicle 10. Accordingly, the seal assembly 100 includes a decorative trim member 128 coupled to the elastomeric seal body 102 to cover a portion of the seal body 102 that would otherwise be visible to the exterior of the vehicle 10. In the illustrated embodiment, the decorative trim member 128 is coupled to the first limb 108 of the seal body 102 and partially wraps around the door frame 14 such that the decorative trim member 128 is exposed to the exterior of the vehicle 10.

[0027] The decorative trim member 128 is formed from a material that is aesthetically pleasing, such as a material exhibiting high gloss (for example, a material having from 80 to 98% gloss) and/or other physical and/or chemical attributes that would contribute to or be consistent with a class A surface of the vehicle 10. In an embodiment, the decorative trim member 128 is formed from a polyvinyl chloride (PVC) material. In embodiment shown in Figures 2-4, the PVC decorative trim member 128 has a mounting portion 130 and an exposed trim portion 132. The mounting portion 130 is formed from a first PVC material and the exposed trim portion 132 is formed from a second PVC material. The second PVC material of the exposed trim portion 132 is a flexible or softened polyvinyl chloride (PVC). Typical properties of flexible PVCs include a density of from 1.15 to 1.45 g/cm ³ measured according to ASTM D792 test method, a tensile yield strength (i.e., the amount of stress the PVC can withstand without permanent deformation) of from 1330 to 3400 psi at 73°F measured according to ASTM D412 test method, and a durometer hardness of from 54 to 92 measured according to ASTM D2240 type A hardness scale with the indentor applied for 15 seconds. Non-limiting examples of suitable flexible PVC materials for the trim portion 132 include VINIKA® soft PVC compounds available from Mitsubishi Chemical Corporation (Tokyo, Japan).

[0028] The second PVC material of the mounting portion 130 may be selected from any PVC material, such as rigid PVC materials, soft PVC materials, and combinations thereof. Typically, the second PVC material of the mounting portion 130 is more rigid (or less flexible) than the first PVC material of the trim portion 132. In other words, the second PVC material may be selected from PVC materials with varying rigidity. Typically, the second PVC material of the mounting portion 130 is much stronger, harder, or more rigid than the flexible PVC of the exposed trim portion 132, enabling the mounting portion 130 to serve as a support for the exposed trim portion 132. Typical properties of rigid PVC materials include a density of from 1.30 to 1.48 g/cm ³ measured according to ASTM D792 test method, a tensile yield strength (i.e., the amount of stress the PVC can withstand without permanent deformation) of from 5550 to 7320 psi at 73°F measured according to ASTM D638 test method, and a durometer hardness of from 75 to 85 measured according to ASTM D2240 type A hardness scale with the indentor applied for 15 seconds. Non-limiting examples of suitable rigid PVC materials include VINIKA® rigid PVC compounds available from Mitsubishi Chemical Corporation (Tokyo, Japan) and SUNPRENE® PVC compounds also available from Mitsubishi Chemical Corporation. In an alternative embodiment, the trim portion 132 and the mounting portion 130 could be formed as a single piece from a single PVC material. In this alternative embodiment, both the trim portion 132 and the mounting portion 130 could be formed from a flexible PVC material exhibiting the desirably high gloss, such as the VINIKA® soft PVC compounds.

[0029] As best shown in Figure 2, the PVC decorative trim member 128 has exterior 134 and interior 136 surfaces with the exposed trim portion 132 defining the exterior surface 134 and both of the exposed trim portion 132 and the mounting portion 130 defining the interior surface 136. At least a portion of the exterior surface 134 of the PVC decorative trim member 128 is exposed to the exterior of the vehicle 10. The exposed trim portion 134 has first 138 and second 140 ends with said first end 134 abutting a portion of said first limb 108 to form a seam 142. As the flexible PVC material of the exposed trim portion 132 is chemically incompatible with the elastomeric seal body 102, the first end 138 of the exposed trim portion 134 does not chemically bond or chemically attach to the first limb 108 of the seal body 102 at the seam 142. Additionally, the exposed trim portion 134 is bendable such that the exposed trim portion 134 curves or bends so that the second end 140 touches the door frame 14 when the seal assembly 100 is installed on the vehicle 10.

[0030] The mounting portion 130 is directly attached to the exposed trim portion 132 of the PVC decorative trim member 128. As the flexible and rigid PVC materials is chemically incompatible, the mounting portion 130 is not directly chemically bonded or attached to the exposed trim portion 132 of the PVC decorative trim member 128. As best shown in Figure 3, the mounting portion 130 has first 144 and second 146 sides and the exposed trim portion 132 has first 148 and second 150 sides, with a segment of the second side 146 of the mounting portion 130 adjacent a portion of the second side 150 of the exposed trim portion 132. The two portions 130, 132 bend or curve so that the PVC decorative trim member 128 wraps around the door frame 14 when the seal assembly 100 is installed. Yet further, the mounting portion 130, which is desirably formed from a rigid PVC material, curves so that the mounting portion 130 and stays in position such that the mounting portion 130 suitably supports the trim portion 132 in position for proper contact with the door frame 14 when the seal assembly 100 is installed. The mounting portion 130 also extends along a portion of the first limb 108 with the second side 146 of the mounting portion 130 facing the door frame 14. Additionally, the exterior surface 114 of the seal body 102 on the first limb 108 and the second side 146 of the mounting portion 130 are complementary in configuration. For example, the seal body 102 on the first limb 108 defines a step 152 and the mounting portion 130 is seated within the step 152 such that the second side 146 of the mounting portion is flush with the exterior surface 114 of the seal body 102.

[0031] Alternatively, the decorative trim member 128 could be formed from any number of distinct pieces, portions, or members. For example, the decorative trim member 128 could be formed from a single portion of PVC material. In another example, the decorative trim member 128 could be formed from two, three, four, or more portions of PVC material, typically bonded to one another to form the decorative trim member 128.

[0032] Molding or extruding the PVC material on or over the elastomeric seal body 102 can be challenging, as the PVC material of the PVC decorative trim member 128 does not form a suitable chemical bond with the elastomeric material of the seal body 102. In other words, the PVC material and the elastomeric materials are chemically incompatible. In the present embodiment, the PVC decorative trim member 128 is coupled to the elastomeric seal body 102 utilizing a tie layer 154. For example, the elastomeric seal body 102 and the PVC decorative trim member 128 are spaced from one another, and the tie layer 154 is sandwiched between the seal body 102 and the PVC decorative trim member 128. This is best shown in Figures 3 and 4, where the tie layer 154 has first 156 and second 158 sides with the tie layer 154 disposed between the elastomeric seal body 102 and the PVC decorative trim member 128 such that the first side 156 faces the elastomeric seal body 102 and the second side 158 faces the PVC decorative trim member 128.

[0033] The tie layer 154 is formed from a metal. The metal of the tie layer 154 is selected from an aluminum alloy, an iron alloy, and combinations thereof. Non-limiting examples of iron alloys include carbon steel, stainless steel, coated steel, electro-galvanized steel, mild steel, tool steel, and/or the like. In an embodiment, the metal of the tie layer 154 is an aluminum foil. In an alternative embodiment, the metal tie layer 154 can be formed from any other suitable metal. Additionally, the metal tie layer 154 may have any suitable configuration, including any suitable length, width, and/or thickness. In an embodiment, the metal tie layer 154 extends partially along the first limb 108. Alternatively, the metal tie layer 154 could extend along the entire first limb 108. In another embodiment, the metal tie layer 154 has a width or thickness of from 0.1 to 1.0 mm.

[0034] The metal tie layer 154 is directly attached to the exterior surface 114 of the seal body 102 on at least a portion of the one of the first 108 and second 110 limbs. In the embodiment shown in Figures 2-4, the metal tie layer 154 is attached to a portion of the first limb 108. More particularly, the metal tie layer 154 is directly attached to the exterior surface 114 of the seal body 102 on a portion of the first limb 108. In the illustrated embodiment, the metal tie layer 154 is seated within the step 152 defined in the first limb 108, and the PVC decorative trim member 128 is also seated in the step 152 adjacent the metal tie layer 154 such that the tie layer 154 is sandwiched between the decorative trim member 128 and the seal body 102. The metal tie layer 154 is directly attached to the portion of the first limb 108 of the seal body 102 utilizing an adhesive 160 specifically formulated to bond an elastomer to a metal. This adhesive 160 is referred to herein as an elastomer-to-metal adhesive 160. As best shown in Figure 4, the elastomer-to-metal adhesive 160 is disposed between the elastomeric seal body 102 and the first side 156 of the metal tie layer 154 to bond the metal tie layer 154 to the elastomeric seal body 102.

[0035] The elastomer-to-metal adhesive 160 may be selected from any adhesive that will suitably bond the elastomer of the seal body 102 to the metal of the metal tie layer 154. One non-limiting example of the elastomer-to-metal adhesive 160 is CHEMLOK® 487 A/B Adhesive available from LORD Corporation (Cary, North Carolina), which has first and second adhesive parts with the first adhesive part including a xylene solvent and the second adhesive part including a methyl isobutyl ketone solvent. CHEMLOK® 487 A/B Adhesive is particularly useful for bonding thermoplastic elastomers to metals, glass, plastics, and other elastomers. Another non-limiting example of the elastomer-to-metal adhesive 160 is THIXON® 6110 available from the Dow Chemical Company (Midland, Michigan), which is a solvent-based adhesive for bonding propylene copolymers to substrates such as metal, glass, and wood.

[0036] The PVC decorative trim member 128 is directly attached to the metal tie layer 154. In the embodiment shown, the mounting portion 130 of the PVC decorative trim member 128 is directly attached to the metal tie layer 154 and the exposed trim portion 132 is directly attached to and supported by the mounting portion 130. Additionally, the metal tie layer 154 is adjacent a portion of the first limb 108 of the seal body 102 and the mounting portion 102 has the first 144 and second 146 sides with the first side 144 of the mounting portion 130 adjacent the metal tie layer 154. Accordingly, the first side 144 of the mounting portion 130 faces the second side 158 of the metal tie layer 154.

[0037] The PVC decorative trim member 128 is directly attached to the metal tie layer 154 utilizing an adhesive 162 specifically formulated to bond PVC (flexible and/or rigid PVCs) to a metal. This adhesive 162 is referred to herein as a PVC -to-metal adhesive 162, and the PVC -to- metal adhesive 162 is different from the elastomer-to-metal adhesive 160. For example, the composition of the PVC-to-metal adhesive 162 is different from the composition of the elastomer-to-metal adhesive 160, rendering the two adhesives 160, 162 as chemically different. As best shown in Figure 4, the PVC-to-metal adhesive 162 is disposed between the PVC decorative trim member 128 and the second side 158 of the metal tie layer 154 to bond the PVC decorative trim member 128 to the metal tie layer 154 to couple the PVC decorative trim member 128 to the elastomeric seal body 102.

[0038] As previously mentioned, the PVC-to-metal adhesive 162 may be selected from any adhesive that will suitably bond the PVC of the decorative trim member 128 to the metal of the metal tie layer 154. One non-limiting example of the PVC-to-metal adhesive 162 is CFIEMLOK® 489/456 Adhesive available from LORD Corporation, which has first and second adhesive parts with the first adhesive part including a methyl isobutyl ketone solvent and a xylene solvent and the second adhesive part including a xylene solvent. CFIEMLOK® 489/456 Adhesive is particularly useful for bonding PVC to metals, glass, and plastics. Another non- limiting example of the PVC-to-metal adhesive 162 is THIXON® 6106 available from the Dow Chemical Company, which is a solvent-based adhesive for bonding PVC to metal substrates including electrogalvanized metals, aluminum, and abraded stainless steels.

[0039] The seal assembly 100 described with reference to Figures 2-4 above may be formed or manufactured utilizing any suitable extrusion process known in the art. In an embodiment, all of the components of the seal assembly 100 are co-extruded to form the seal assembly 100. In particular, the seal body 102, the PVC decorative trim member 128 (including the mounting portion 130 and the exposed trim portion 132), the PVC-to-metal adhesive 162, the metal tie layer 154, and the elastomer-to-metal adhesive 160 are co-extruded. In instances where the seal assembly 100 includes a metal carrier, the seal body 102, the PVC decorative trim member 128, the PVC -to-metal adhesive 162, the metal tie layer 154, and the elastomer-to-metal adhesive 160, and the metal carrier are co-extruded.

[0040] Another embodiment of the seal assembly 200 is described below with reference to Figures 5, 5A, and 6. In this embodiment, the seal assembly 200 includes a seal body 202 having a closed end 204, an open end 206 opposite the closed end 204, and first 208 and second 210 limbs extending from the closed end 204 toward the open end 206. The closed end 204, the first limb 208, and the second limb 210 define a first channel 216 for receiving at least the edges 20 of the movable window closure member 18. Additionally, the closed end 204, the first limb 208, and the second limb 210 define an interior surface 212 of the seal body 202, which defines the first channel 216.

[0041] The first 208 and second 210 limbs of the seal body 202 also extend from the closed end 204 in a first direction. The seal body 202 further has a third limb 264 extending from the closed end 204 in a second direction opposite the first direction. The third limb 264 is aligned with the second limb 210. The third limb 264 extends from the closed end 204 and terminates at an end 266. In an embodiment, the third limb 264 defines a notch 265 and a slot 267 adjacent the notch 265. Both the notch 265 and the slot 267 are proximate the end 266 of the third limb 264. Additionally, the closed end 204, the first limb 208, the second limb 210, and the third limb 264 define the exterior surface 214 of the seal body 202.

[0042] Many details of the configuration of the seal body 202 and the first channel 216 of the seal assembly 200 are the same as previously described for the seal body 102 and the first channel 116 of the seal assembly 100. In this embodiment, however, the seal body 202 includes just second 220 and third 222 sealing lips, with the second sealing lip 220 extending from the second limb 210 toward the first channel 216 and the third sealing lip 222 extending from the first limb 208 toward the first channel 216. The second 220 and third 222 sealing lips extend toward one another and are biased toward the first channel 216 to form a seal between the movable window closure member 18 and the door frame 14 when the movable window closure member 18 is received within the first channel 216. In an embodiment, the second sealing lip 220 may be formed from an elastomeric material that is different (such as more flexible) from the closed end 204, first limb 208, second limb 210, and third limb 264 of the seal body 202, and may be considered a separate component of the seal body 202. Similarly, the third sealing lip 222 could also be formed from an elastomeric material that is different (such as more flexible) from the closed end 204, first limb 208, second limb 210, and third limb 264 of the seal body 202. In the embodiment shown, the second sealing lip 220 have a main portion 284 and a lip portion 286, with the main portion 284 formed on at least partially on the exterior surface 214 of the seal body 202 adjacent the second limb 210. The main portion 284 defines a stop 288. It should be appreciated that the seal body 202 could include any number of sealing lips formed on each of the first 208 and second 210 limbs.

[0043] The seal body 202 is formed from an elastomer selected from EPDM rubber, TPV, and combinations thereof, as detailed above. In an embodiment, the closed end 204, the first limb 208, and the second limb 210 are formed from a more rigid elastomer, and the sealing lips 220, 222 are formed from another more flexible elastomer enabling the sealing lips 220, 222 to flex or bend when the movable window closure member 18 is received in the first channel 216.

[0044] The seal assembly 200 further includes the metal carrier 274 disposed in the seal body 202. In one configuration, the metal carrier 274 is embedded in the seal body 202 and extends along the closed end 204, the first limb 208, the second limb 210, and the third limb 264. The metal carrier 274 also extends at least partially along the length of the seal body 202. The metal of the metal carrier 274 may be chosen from any metal that will suitably provide rigidity and/or stability to the seal body 202. Non-limiting examples of suitable metals for the metal carrier 274 have been identified above in connection with the seal assembly 100 description.

[0045] As best shown in Figure 5A, the seal body 202 defines a mold region 268 extending along a portion of the exterior surface 214 of the seal body 202. In the illustrated embodiment, the mold region 268 extends along a portion of the closed end 204 and along at least a portion of one side of the third limb 264. The mold region 268 is a region of the seal body 202 along the exterior surface 214 to which a layer 270 of elastomeric material is coupled or attached, such as over-molded. The layer 270 may be formed from any suitable elastomer, such as the elastomers described above in connection with the seal body 202 materials. Alternatively, the layer 270 could be formed from other elastomeric materials not specifically mentioned above. The layer 270 also defines a second channel 271 for receiving the fixed window closure member 22 of the vehicle 10. In the embodiment shown, the second channel 271 is opposite and substantially parallel (such as 180° relative) to the first channel 216. [0046] As also shown in Figure 5A, the seal body 202 further defines a trim portion 272 extending along another portion of the exterior surface 214 of the seal body 202. As shown, the second 210 and third 264 limbs at least partially define the trim region 272. The trim region 272 is a region of the seal body 202 along the exterior surface 214 to which a metal tie layer 254 is coupled. As shown, the trim region 272 extends from the notch 265 defined by the third limb 264 of the seal body 202, along the third limb 264, and at least partially along the second limb 210.

[0047] In the present embodiment, the PVC decorative trim member 228 is formed from a flexible PVC material, such as any of the flexible PVC materials previously described for the trim portion 132 of the PVC decorative trim member 128 of the seal assembly 100 above. Additionally, the PVC decorative trim member 228 is directly attached to the metal tie layer 254 and extends at least partially along the trim region 272 defined by the exterior surface 214 of the seal body 202. The PVC decorative trim member 228 has opposing first 276 and second 278 ends and exterior 234 and interior 236 surfaces. The interior surface 236 faces inwardly toward the seal body 202 and the exterior surface 234 faces outwardly and is exposed to the exterior of the vehicle 10. The PVC decorative trim member 228 conforms to the contour of the seal body 202 (particularly, the second 210 and third 264 limbs), with the first end 276 abutting the third limb 264 of the elastomeric seal body 202. As shown, the first end 276 of the PVC decorative trim member 228 is adjacent and abuts the notch 265. Additionally, the second end 278 of the PVC decorative trim member 228 is adjacent and abuts the stop 288 defined by the main portion 284 of the second sealing lip 220.

[0048] As mentioned above, the PVC decorative trim member 228 cannot be directly attached to the elastomeric seal body 202 due to the chemical incompatibility of the PVC material of the PVC decorative trim member 228 the elastomeric material of the seal body 202. Accordingly, the PVC decorative trim member 228 is coupled to the seal body 202 in this embodiment utilizing the metal tie layer 254. For example, the elastomeric seal body 202 and the PVC decorative trim member 228 are spaced from one another, and the metal tie layer 254 is sandwiched between the seal body 202 and the PVC decorative trim member 228. This is best shown in Figure 6, where the metal tie layer 254 has the first 256 and second 258 sides with the metal tie layer 254 disposed between the seal body 202 and the PVC decorative trim member 228 such that the first side 256 faces the seal body 202 and the second side 258 faces the PVC decorative trim member 228.

[0049] The tie layer 254 is formed from a metal as previously described for the seal assembly 100. The metal tie layer 254 may have any suitable configuration, including any suitable length, width, and/or thickness as also previously described. Additionally, the metal tie layer 254 has opposing first 280 and second 282 ends with the opposing first 256 and second 258 sides extending between the ends 280, 282. The metal tie layer 254 is directly attached to the exterior surface 114 of the seal body 202 along the trim region 272 utilizing an adhesive 260 specifically formulated to bond an elastomer to a metal (an elastomer-to-metal adhesive). The formulation of the elastomer-to-metal adhesive 260 is the same as previously described for the elastomer-to- metal adhesive 160 for the seal assembly 100. As also shown in Figure 6, the elastomer-to-metal adhesive 260 is disposed between the elastomeric seal body 202 and the first side 256 of the metal tie layer 254 to bond the metal tie layer 254 to the elastomeric seal body 202.

[0050] In an embodiment, the metal tie layer 254 may also be mechanically interlocked to the seal body 202. For example, and as best shown in Figures 5 and 5A, the third limb 264 defines the slot 267 and the metal tie layer 254 has the opposing first 280 and second 282 ends with the first end 280 forming a hook 290, with the hook 290 disposed in the slot 267 to mechanically interlock the metal tie layer 254 to the third limb 264 of the elastomeric seal body 202. It should be appreciated that alternative mechanical interlocking configurations of the metal tie layer 254 are also contemplated. For example, one or both of the first 280 and second 282 ends of the metal tie layer 254 could be configured to form a mechanical interlock with the underlying seal body 202 not necessarily by a hook/slot arrangement. In yet another alternative configuration, the third limb 264 may have no slot 267 and the metal tie layer 254 may be formed such that the first end 280 does not form the hook 290. In this alternative configuration, the metal tie layer 254 would be chemically attached to the seal body 202 alone, i.e., without or in the absence of a mechanical interlock.

[0051] The PVC decorative trim member 228 is directly attached to the metal tie layer 254 and extends along the trim region 272. In the embodiment shown, and as previously mentioned, the PVC decorative trim member 228 extends partially along the trim region 272 with the second end 278 of the PVC decorative trim member 228 terminating short of the second end 282 of the metal tie layer 254 and abutting the main portion 284 of the sealing lip 220. In this configuration, and as best shown in Figure 5, the second end 282 of the metal tie layer 254 is tucked between the main portion 284 of the sealing lip 220 and the second limb 210 of the seal body 202. Alternatively, the decorative trim member 228 could extend along the entire length of the trim region 272. In this alternative configuration, the metal tie layer 254 could terminate at the stop 288 of the second sealing lip 220 and would not be tucked between the main portion 284 of the sealing lip 220 and the second limb 210 of the seal body 202.

[0052] The PVC decorative trim member 228 is directly attached to the metal tie layer 254 utilizing an adhesive 262 specifically formulated to bond PVC to a metal (a PVC -to-metal adhesive). The formulation of the PVC -to-metal adhesive 262 is the same as previously described for the PVC -to-metal adhesive 160 for the seal assembly 100, and the PVC -to-metal adhesive 262 is different from the elastomer-to-metal adhesive 260. As shown in Figure 6, the PVC -to-metal adhesive 262 is disposed between the PVC decorative trim member 228 and the second side 258 of the metal tie layer 254 to bond the PVC decorative trim member 228 to the metal tie layer 254 to couple the PVC decorative trim member 228 to the elastomeric seal body 202.

[0053] In the embodiment shown in Figures 5, 5A, and 6, the elastomeric seal body 202, the elastomer-to-metal adhesive 260, the metal tie layer 254, and the PVC -to-metal adhesive 262 may be formed by any suitable co-extrusion process, and the PVC decorative trim member 228 may be formed by molding the PVC material over the metal tie layer 202 at least partially along the trim region 268. Typically, the metal carrier 274 is co-extruded with the elastomeric seal body 202, the elastomer-to-metal adhesive 260, the metal tie layer 254, and the PVC -to-metal adhesive 262. Additionally, the layer 270 (defining the second channel 271) is molded to the seal body 202 along the mold region 268. In an embodiment, the layer 270 and the PVC decorative trim member 228 are molded to the extrudate (i.e., the co-extrusion product of the elastomeric seal body 202, the elastomer-to-metal adhesive 260, the metal tie layer 254, and the PVC -to-metal adhesive 262) at substantially the same time. Such a process may be referred to as a two-shot molding process.

[0054] Another embodiment of the seal assembly 300 is described below with reference to Figures 7 and 7A. In this embodiment, the seal assembly 300 includes a seal body 302 having a closed end 304, an open end 306 opposite the closed end 304, first 308 and second 310 limbs extending from the closed end 304 in a first direction toward the open end 306, and a third limb 364 extending from the closed end 304 in a second direction opposite the first direction. The closed end 304, the first limb 308, and the second limb 310 define a first channel 316 for receiving the movable window closure member 18 of the vehicle 10. Additionally, the closed end 304, the first limb 308, and the second limb 310 define an interior surface 312 of the seal body 302. The closed end 304, the first limb 308, the second limb 310, and the third limb 364 define an exterior surface 314 of the seal body 302. The seal body 302 further has second 320 and third 322 sealing lips with the second sealing lip 320 extending inwardly from the second limb 310 and the third sealing lip 322 extending inwardly from the first limb 308. Additionally, the seal assembly 100 includes a metal carrier 374 disposed in the seal body 302.

[0055] The details of the foregoing features of the seal body 302 are the same as previously described in connection with the seal body 202 of the seal assembly 200 shown in Figures 5, 5A, and 6. Additionally, the seal body 302 is formed from an elastomer selected from EPDM rubber, TPV, and combinations thereof, as also described above.

[0056] As best shown in Figure 7a, the seal body 302 defines a mold region 368 extending along a portion of the exterior surface 314. In the illustrated embodiment, the mold region 368 extends along a portion of the closed end 304 and along at least a portion of the third limb 364. The mold region 368 defines a region of the seal body 302 along the exterior surface 314 that a layer 370 of elastomeric material is coupled, such as over-molded. The layer 370 may be formed from any suitable elastomer, such as any of the elastomers described above in connection with the seal body 302 materials. Alternatively, the layer 370 could be formed from other elastomeric material(s) not specifically mentioned above. The layer 370 also defines a second channel 371 for receiving the fixed window closure member 22 of the vehicle 10. In the embodiment shown, the second channel 371 is opposite and substantially parallel (such as 180° relative) to the first channel 316.

[0057] The seal body 302 further defines a trim region 372 extending along another portion of the exterior surface 314. The second 310 and third 364 limbs define the trim region 372. Along the trim region 372, the seal body 302 defines a plurality of locking cavities 392. More particularly, the locking cavities 392 are defined along the third limb 364 and at least partially along the second limb 310. The locking cavities 392 may have any suitable configuration, and extend at least partially along a length of the seal body 302. In the embodiment shown, each of the locking cavities 392 has a neck portion 394 and a body portion 396 extending from the neck portion 394. The body portion 396 may have a larger width in cross-section compared to the neck portion 394. In an embodiment, the locking cavities 392 have a dovetail-like configuration in cross-section. Alternatively, the locking cavities 392 could have any other suitable locking- type configuration.

[0058] The seal assembly 100 further includes a decorative trim member 328 formed from a PVC material. As previously mentioned, the PVC material of the decorative trim member is chemically incompatible with the elastomer of the seal body 302. Rather than utilizing a metal tie layer, in the present embodiment, the PVC decorative trim member 328 is mechanically attached to the seal body 302. For example, the PVC decorative trim member 328 has exterior 334 and interior 336 surfaces and a plurality of locking features 398 extending from the interior surface 336. Each of the locking features 398 has a stem portion 400 and a head portion 402 extending from the stem portion 400. The locking features 398 are formed inside the locking cavities 392 when the PVC decorative trim member 328 is molded on the seal body 302 to mechanically interlock the PVC decorative trim member 328 to the seal body 302, as best shown in Figure 7. With a mechanical interlock, no metal tie layer or adhesives are required for coupling the PVC decorative trim member 328 to the seal body 302.

[0059] In an embodiment, the plurality of locking cavities 392 and the plurality of locking features 398 are complementary in configuration. For example, the head portion 402 of each of the locking features 398 has a configuration complementary to the body portion 396 of each of the locking cavities 392 defined in the seal body 302. In the embodiment shown, the head portion 402 of the locking features 398 and the body portion 396 of the locking cavities 392 have a dovetail-like configuration in cross-section. Alternatively, the head portion 402 and the body portion 396 could have other suitable configurations.

[0060] The seal assembly 300 may be formed by extruding an elastomer to form the seal body 302 having the trim region 372 and the plurality of locking cavities 392 along the trim region 372. In an embodiment, the extruding step may be further defined as co-extruding the elastomer and a metal to form the seal body 302 having the metal carrier 374 disposed in the seal body 302. The extrusion (or co-extrusion) may be accomplished utilizing any suitable extrusion process known in the art to form the seal body 302 (or the seal body 302 including the metal carrier 374).

[0061] The method further includes the step of molding the PVC material over the trim region 372 of the seal body 302 such that the PVC material flows into the plurality of locking cavities 392 to mechanically interlock the decorative trim member 328 with the seal body 302. In an embodiment, the method further includes molding another elastomer over the mold region 368 to form the layer 370. In an embodiment, the molding of the elastomer to form the layer 370 occurs substantially simultaneously with the molding of the PVC material to form the decorative trim member 328. Such a process may be referred to as a two-shot molding process.

[0062] The embodiment of the seal assembly 100 described above may be used to form a seal between the movable window closure member 18 and the door frame 14 defined in the vehicle door 12, and the embodiments of the seal assembly 200, 300 described above may be used to form a seal between the movable 18 and fixed 22 window closure members and the door frame 14 defined in the vehicle door 12. Since the PVC decorative trim member 128, 228, 328 has high gloss, the PVC decorative trim member 128, 228, 328 contributes to a desirable class A surface when visible from the exterior of the vehicle 10. Additionally, while the seal assembly 100, 200, 300 may be utilized for forming a seal between a window closure member and a window frame, it should be appreciated that the seal assembly 100, 200, 300 could also or otherwise be configured for use in sealing other openings in the vehicle 10, such as trunk or decklid openings, door openings, and/or sunroof openings. It should further be appreciated that the seal assembly 100, 200, 300 could also be used for other purposes not specifically related to vehicles, such as for homes, buildings, boats, etc.

[0063] The invention has been described in an illustrative manner, and it is be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. It is now apparent to those skilled in the art that many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described.