Technical Field of the Invention

The present invention relates to side doors for motor vehicles generally, and in particular, to a method of assembling water barriers in a vehicle door.

BacJ gnMindjo the Invention

In the automotive industry, vehicle door assembly traditionally has comprised the step of joining two or more pieces of metal to form an exterior panel and an interior panel of the door. The exterior panel comprises two elements: the window support section; and the housing section. The window support section corresponds to the peripheral contour of the window and connects to the housing section of the exterior panel. The exterior panel is shaped and colored to continuously conform to the remainder of the vehicle body.

Subsequently, the interior panel is joined to the exterior panel along the edges of the housing section to form a cavity within the center of the door. The interior panel may carry the wiring for the door components. A trim panel is then attached to the interior panel of the vehicle door. The trim panel is employed on the vehicle interior essentially for decoration, while also providing an arm rest for the vehicle's passengers.

The cavity formed in the vehicle door allows space for the mechanical parts to be housed in the door. For example, a door window must enter the cavity when the window is lowered. Likewise, the cavity is also needed to provide the space

required for the lock, the window motor, the radio speakers, as well as other components.

Traditionally, the interior panel is constructed with a pathway in the center of the panel to allow access to the parts housed in the door cavity. The pathway, however, can cause insulation problems with respect to water generally, and rain particularly. Water may penetrate a door's cavity through the opening in which the door window enters and exits the cavity. Rain water entering the cavity travels down the panels and leaves the door cavity through holes at its bottom. Some rain water, however, may travel through both the pathway in the interior panel and the trim panel into the vehicle's interior. Without a means for deflecting the rain water away from the trim panel stationed within the pathway, the rain water will damage both the trim and the wiring in the trim.

One solution to this problem is to construct vehicle doors having a water barrier placed over the pathway. The water barrier functionally stops the rain water from penetrating the vehicle interior by directing it out of the cavity through the holes in the bottom of the cavity. As a benefit, the water barrier may be made out of a material that will deflect sound from entering the vehicle interior.

The water barrier is secured to the door interior panel before the trim panel is attached to the interior panel. If affixed correctly, the water barrier will keep the water from damaging the vehicle interior and the trim panel. However, this method of coupling the water barrier to the interior panel sometimes causes the water barrier to tear and form holes through which rain water may penetrate. Likewise, this method of coupling causes the water barrier to wrinkle. Wrinkled water barriers will not deflect all of the rain water, enabling some to permeate into the trim panel and cause damage.

Therefore, a method is needed of placing the water barrier into a vehicle door that does not cause the water barrier to wrinkle or form holes.

The primary advantage of the present invention is to overcome the limitations of the prior art.

Another advantage of the present invention is to provide a method of placing the water barrier into a vehicle door that does not cause the water barrier to wrinkle or form holes.

In order to achieve the advantages of the present invention, a method is disclosed for assembling a water barrier between two panels. The method initially comprises the step of forming a shoulder along the periphery of the water barrier.

Subsequently, one of the panels is engaged with the water barrier. Finally, an adherent is applied to the shoulder, and the water barrier is coupled to the second panel.

These and other objects, features and advantages of the present invention will become more apparent to those skilled in the art in light of the following detailed description of and drawings attached thereto.

Brief Description of the Drawings

The present invention will be better understood from reading the following description of non-limitative embodiments, with reference to the attached drawings, wherein below:

FIG. 1 is an exploded view of the door of the present invention;

FIG. 2A is a cross-sectional view of the water barrier of the present invention, while FIG. 2B is a cross-sectional view of an alternative embodiment of the water barrier of the present invention; and

FIG. 3 A is a cross-sectional view of an aspect of the invention, while FIG. 3B is an exploded view of the water barrier and the trim panel of the present invention.

It should be emphasized that the drawings of the instant application are not to scale but are merely schematic representations and are not intended to portray the specific parameters or the structural details of the invention, which can be determined by one of skill in the art by examination of the information herein.

Delaile LDescription of the Preferred Embodiments

Referring to FIG. 1, an exploded view of a fully assembled vehicle side door 20 is depicted. Door 20 comprises an exterior panel 23, an interior panel 26, a water barrier 29 and a trim panel 32. The interior panel 26 and the water barrier

29 are disposed between the exterior panel 23 and the trim panel 32. The exterior panel 23 is shaped and colored to conform with the rest of the vehicle body, the interior panel 26.

The exterior panel 23 is preferably a continuous unit comprising a window support section 41 and a housing section 44. An alternate exterior panel may comprise only the housing section 44. The window support section 41 secures a door window 47 when the window 47 is fully raised. The interior panel 26 is mounted to the housing section 44 to form a cavity 50 wherein various parts

including several mechanical components are situated. For example, the door window 47 enters the cavity 50 when the window 47 is lowered. Other mechanical parts may be positioned into the cavity 50 including a lock, a window motor, a radio speaker, and other components

Set into the interior panel 26 are a plurality of pathways 53 to allow access to the cavity 50 for placement and repair of the mechanical parts. The number, the location and the configuration of the pathways 53 in the interior panel 26 as depicted in FIG. 1 are meant to be illustrative of the positions and locations of the pathways 53 which can be utilized. The actual number, location and configuration of the pathways 53 in the interior panel 26 will be a function of the desired layout of the mechanical parts in the cavity 50.

The water barrier 29 is coupled to the interior panel 26. The pathways 53 are covered by the water barrier 29 to impede the flow of water into the vehicle.

The water barrier 29 is preferably made of a material that will deflect sound, as well as water, from carrying into the vehicle. The water barrier 29 is also preferably made of a material that is pliant. A flexible foam will preferably divert sound and water from entering the vehicle. In the preferred embodiment, the barrier 29 comprises closed cell foam.

Connected to the water barrier 29 and the exterior panel 23 is a trim panel 32. The trim panel 32 is employed in the vehicle for decoration. Moreover, the trim panel 32 provides an arm rest to the vehicle's passengers.

The method of assembling the water barrier 29 between the interior panel 26 and the trim panel 32 according to the preferred embodiment comprises several steps. Initially, the water barrier 29 is formed with a shoulder 56 along a peripheral edge 59 of the water barrier 29. The contour of the water barrier 29 corresponds

to the shape of the interior panel 26. The water barrier 29 is best formed using a process of vacuum molding. Alternative methods of forming the water barrier 29, such as pressure forming, should be apparent to those skilled in the art in light of the present invention.

• 5

The shoulder 56 of the water barrier 29 is depicted as a rise in a U shaped configuration in FIGS. 1 and 2A. It should be noted, however, that alternatively, the shoulder 56 may comprise other configurations including a W shape, an "n" shape and an "m" shape. FIG. 2B depicts an alternative embodiment of the water

10 barrier of the present invention. The actual shape for the shoulder 56 will vary depending on the desired surface area for the rise of the shoulder 56. The perimeter of the shoulder 56 preferably covers three sides of the peripheral edge 59 of the water barrier 29, although four-sided coverage also deflects the water.

15 Subsequently, the water barrier 29 is engaged with the trim panel 32. As depicted in FIGS. 3 A and 3B, the step of engaging is preferably accomplished by projecting a plurality of studs 66 mounted on the trim panel 32 through a plurality of holes 67 located in the water barrier 32. The studs 66 are preferably long enough to hold the water barrier 32 onto the studs 66 without requiring a glue. Glue may, 0 however, be employed for additional holding the water barrier 32 onto the studs 66.

In an alternate embodiment, however, studs 66 are replaced by use of an automated robotic process, or a different fixture format.

An adhesive 68 is then applied to the shoulder 56 of the water barrier 29. 5 A pressure sensitive glue is the preferred adhesive. The adhesive 68 preferably is applied to the shoulder 56 to produce a strip of adhesive 68.

Thereafter, the water barrier 29 is coupled to the interior panel 26. The water barrier 29 is preferably coupled to the interior panel 26 by manually

compressing the shoulder 56 between the trim panel 32 and the interior panel 26. The shoulder 56 as a result will become planar and adhere to the interior panel 26. The trim panel 32 is then secured with the interior panel 26 and the exterior panel 23 by methods well known by those skilled in the art. The preferred method of securing the trim panel 32 the exterior panel 23 employs a conventional Christmas tree fastener. Alternative securing methods, including hanging the trim panel 32 on hooks positioned on the exterior panel 32 and screwing the trim panel 32 to the exterior panel 32, should be apparent to those skilled in the art in light of the present invention.

In an alternative embodiment of the present invention, the step of coupling does not require an adhesive 68 for forming the seal. Rather, the water barrier 29 is coupled to the interior panel 26 by solely compressing the water barrier 29 between the interior panel 26 and the trim panel 32. Here, the step of compressing the water barrier causes a seal to be formed due to the characteristics and properties of the materials at issue, such as compressible formed foam.

While the particular invention has been described with reference to illustrative embodiments, this description is not meant to be construed in a limiting sense. It is understood that although the present invention has been described in a preferred embodiment, various modifications of the illustrative embodiments, as well as additional embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description without departing from the spirit of the invention, as recited in the claims appended hereto. Thus, for example, it should be apparent to one of ordinary skill in the art that while the present invention is applicable to vehicular doors, it is also suitable in conjunction with other vehicle body parts, as well as other interior systems, such as mobile homes and home interiors, and the like. Similarly, it should be apparent to one ordinary skill in the art while the barrier system of the present invention has been detailed as water

barrier, other barriers including sound, for example, are available which would take full advantage of the present invention. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention.