CA2095380A1

CA2095380A1 - Vehicular panel assembly and method for making same

Info

Publication number: CA2095380A1
Application number: CA002095380A
Authority: CA
Inventors: Raj Kumar Agrawal; Doug Crank
Original assignee: Donnelly Corp
Current assignee: Magna Donnelly Corp
Priority date: 1992-06-12
Filing date: 1993-05-03
Publication date: 1993-12-13
Also published as: JPH06297940A; DE69305921D1; US5331784A; US5440849A; MX9302914A; EP0576180B1; DE69305921T2; US5611180A; EP0576180A1

Abstract

VEHICULAR PANEL ASSEMBLY AND METHOD FOR MAKING SAME

ABSTRACT OF THE DISCLOSURE
A panel assembly and method of manufacturing the panel assembly, especially adapted for use in vehicle panels, include locating a preformed gasket in a support fixture in a predetermined pattern to be bonded to a sheet-like panel. The gasket is formed from a polymeric material separately from the panel The panel is of appropriate size and geometry to fit within a desired vehicle opening. At least one panel surface to receive the gasket is prepared by being primed with a bonding reagent.
The panel and primer may be preheated before receiving the gasket to drive off remaining carriers/solvents and improve the bonding process. The panel and preset gasket are pressed together such that the securing flange is in intimate contact with the panel. Locator pins may be used to properly position the panel with respect to the gasket.
Once located, heat and pressure are applied, preferably substantially simultaneously, the heat being applied from a side opposite the primed surface, preferably by focused or tuned infrared irradiation.

Description

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. 1 VEIIlCl3I,i~ ANEL A.S_ EMBL ANI) Ml~,'rllOD FOR MAI~ING SAMI', BACKGROTJND OF Tl~ N
This invention relates to panel assemblies espec~ally adapted for use as w:indows in vhicle~, buil~incJs or other structures, as well as a method Eor manufacturincJ
such panel assemblies.
Relatively recent in t:he history of vehicle panel ~ssemblies, gaskets have beQn molded or extruded directly onto the window panel. In molded window panels, a sheet of glass is closed within a molding tool and a polymeric material is then injected around the opposing surfaces of the peripheral adge, thereby capturing the peripheral edge of the glass panel within the injected polymeric gasket.
After the gasket is cured or hardened, the mold is opened and the panel assembly is removed. To retain the molded panel assembly within the vehicle, stUds or clips may be molded within the gasket and used to engage the pinch weld flange forming the vehicle opening. Alternately, or in addition, a bead of adhesive is also often applied to bond ~ the glass panel and gasket directly to the pinch weld flange. A decorative bezel may be molded with the gasXet to conceal space between the vehicle and the window assembly.
A disadvantage with molding gaskets directly onto the glass panel is the not infre~uent breakage of the glass panel during the molding process. Glass panels are not perfectly uniform and are occasionally crushed when the molding tool is closed about the panel.
New styling requirements are calling for flush mounted glass panels haviny an exposed edge. One flush mounted vehicle panel assembly on the market includes extruded gaskets deposited directly on one surface of a 2 ~ .3 j ~3 ~ O

glass sheet. Often the extrusion includes two adhesive beads o~ polyurethene compounds, one deposlted by the panel assembly manu~actur~r and th~ other applle~ by the vehlcle assembler. Disadvantages associated wlth extruded yaskets include long cure time for the i-`irst bead, adding cycle time tG manufacturing, and constant c:ross-sectional profiles. In addition to beincJ limited to uni.form cross-sectional profiles, the gasket material used in forming extruded gaskets is typically not UV stable by itself and can deyrade over time. Moreover, the extrusion does not easily adapt itself to receive mountiny studs or clips. The extrusion compound is expensive and requires special storage and handling once formed and cannot be fully completed without creating a seam or gap in the gasket layout.
Another window assembly intended for use in flush mounted applications had a gasket molded directly to a single surface in a molding machine using reaction injection molded (RIM) urethane. Although thls technique offered some variable cross sections, the presence of the glass and tooling limitations prevented or precluded gaskets having undercuts or lipso Other disadvankages include instability when subjected to prolonged exposures of ultraviolet light, long cycle times in forming, and increased material costs compared with other materials such as PVC. In addition, tensile or sh~ar forces applied between the glass and gasket rasult ~n failure of the adhesive seal of the gasket with the panel as opposed to the desired loss of cohesion in the gasket itself.
None of the prior panel assemblies or methods are as versatile in providing flush mounted panel gaskets having unique cross-sectional profiles, with or without attaching . 1 or otherwise capturing fasteners. Moreover, none o~ the prior method~ or panel assemblies can provide flush mounte~
panel yaskets having cross-sectio~lal profiles which are variable ~long the panel assembly and satisfy complex sealiny requirements.
SUMMARY OF' T~IE INVENTION
The present invention iilcludes a uni~ue panel assembly, especially ~or vehicles, and method for manufacturing the panel assembly.
The method o~ this invention is pre~erred in the manufacture o~ a panel assembly especially suited ~or use in vehicles. More particularly, the method is used to manu-facture window panel assemblies for vehicles wherein the glass panel is flush-mounted within the vehicle opening and sealed therein by one or more gaskets or grommets bonded to a single surface of the panal. Moreover, the method includes adhering a polymeric gasket or grommet to a single surface of a vehicle panel so that the panel may be mounted flush with the vehicle exterior. The method includes the - steps of preparing a surface area of the panel adapted to receive the gasket using a material specially adapted to ~ond the panel with the gasketO The desired gasket pro~ile is formed from a polymeric material separately from the glass panel. The desired gasket is then located with respect to the panel and heat and pressure are applied to the contact boundary to establish the bond.
In onle embodiment o~ the method, the panel and gasket are preheated. Heat is applied to the panel to improve adhesion to the gasket. The gasket is heated to make it more pl:iable and promote adhesion. Tha preheated ~ ' panel is po~itioned on the yasket and pressed into intima-te contact.
In another ~orm o~ the method, the panel assembly, especially adaPted for US3 in vehicle ~indows, includes th~
steps of priming a surface of the panel adapted to receive th~ gasket, using a material especiall~ adapted to prepare the panel surface to kond Wit}l t:he gaslcet and allowed to dry. Drying time may be decreased by preheating the panel to drive off any carriers/solvenks in the primer coating and to elevate the eneryy level of the bonding agents.
Preheating of the panel may be reduced or eliminated by applying the primer to the gasket surface. Moreover, if preheating is desired, heat may be applied to the panel.
Additional heat may also be applied to the interface between the panel and gasket when the panel is ~orced against the gasket. The additional heat is preferably directed upon a frit layer between the panel and the gasket to ~urther the bonding process.
The panel assembly of this invention is formed according to the method outlined above and includes a sheet-like panel of predetermined size and geometry. The panel has two surfaces terminating in a peripheral edge, one of which may have a cosmetic ceramic frit coating to conceal the vehicle opening and the manner in which it is attached to the vehicle. A primer coating is applied to the panel surface adapted to receive the gasket and is applied to a restricted area proximatP the peripheral edge. The gasket is formed separately from the panel and bonded to the primecl surface by the application of heat and pressure. A securing flange or surface of the gasket defines a bonding surface adapted to engage the panel and which may retain mounting 3 ~ ~
. 1 hardware to retain th~3 pdnel .in the vehicle. The resul-ting product made according to ths method is a sheet-like panel haviny,a gasket securely attached to at :least a por~ion OL
at least one surfac of the panel and lnstalled as a unit securely within the opening from the exkerior.
The panel assemblies and the method of manu-facturing tnem have advantages over the prior art in that the gasket may be mass produced separate from the panel using conventional extrusion or molding techniques.
Moreover, the assembly may be accomplished without complex machines to ~ix the gasket to the panel. 2~oreover, because bonding the gasket to the panel rec~uires lower pressures than direct molding techniques, fewer panels are broken during the manufacturing process and less waste results.
Yet another advantag~ o~ the panel ~ssembly and the method of making i~ is the ability to install the panel assembly in existing vehicles with specific gasket designs *or sealing the panel assembly in the vehicle.
These and other objects, advantages, purposes and features of the inven~ion will become more apparent from a study of the following description taken in conjunction with the drawings described below.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a fragmentary plan view of a generic ~5 panel assembly of this invention;
Figs. 2A and 2B are fragmentary, cross-sectional views taXen along line II-II of Fig. 1:
Figs. 3A-3L schematically illustrate one embodiment of the method and panel assembly;
Figs,. ~A-~G illustrate one embodiment of a machine used to carry out the method;

2~39~3~0 F:iys. 5 and 6 ar~ two plan v:iews of machine components shown in Fig. ~;
Figs. 7 illustrates an alterna~e ~echnlque use~ in the method of this invention;
Figs. 8 and 3 schematically illustrate heating devices which may be used in this invention; and Figs. 10 and 11 generally illustrate alternate embodiments of panel assemblies made in accordance with the method.
DETAILED DESCRIPTION OF THE PREFERRED ~ ODIMENTS
In the following description, re~erence will be made to "gaskets" and "grommets," and will be used inter-changeably herein to refer to strip, elongated or string-like seals, as well as complete loop seals, extruded and molded, and adapted to be placed between two or more surfaces. Although the following description will be made primarily with reference to a gask~t made from extruded materials, this is not to be construed as a limitation but is provided merely by way of illustration. The method and panel assembly produced according to the method may also be accomplished using gaskets preformed using injection moldin~
techni~ues, of which specific examples are described in detail below.
Referring now to the drawing figures in greater detail, Figs. 1 and 2A illustrate one embodiment 20 of the window panel assembly o~ the present invention specifically adapted for use in a vehicle as a window and includes a panel or sheet of glass 22 which may be tempered, laminated, or otherwise strengthened using conventional techniques.
Sheet 22 has two substantially parallel sides or faces 24, 26 which terminate in a peripheral edge 2~o Although a 3 ~ ~1 . 1 transparent slleet o~ ylass is p:re-ferrecl, oth r panel materials such as opaque tinted glass, or transparenk, tinted, or opaque plastic ma~erla.Ls, or multi-composite laminates such as glass and plastic could also be us~d.
Panel assembly 20 is of a part.icular size and geometry adapted to fit within and conform to a window openiny 30 formed by shee-t metal pi.nch flange 32 of the vehi.cle body.
Fixed to inner sur~ace 24, and extending aloncJ and around at least a portion of sheet 22 proximate peripheral edge 28, is a flexible, resilient gasket or grommet 40 intended to provide a weather seal with a portion of a vehicle body when assembly 20 is installed. In Fig~ 1, gasket 40 is shown ko extend around the entire perimeter of surface 2~, disposed between sheet metal pinch flange 32 and ~5 sheet 22. Gasket 40 may be fixed to a ceramic frit layer 38 (Fig. 2A) applied and bonded to a restricted area on surface 24 proximate peripheral edge 28 to cosmetically conceal gasket 40 and pinch weld flange 32. Alternately, gasket 40 may be ~ixed directly to surface 24 of sheet 22 if frit - layer 38 is not used.
Gasket 40 is preferably resistant to ultraviolet radiation and preformed using conventional extruding or molding techniques from an elastomeric material, such as polyvinyl chloride (PVC) or RIM urethanes. Other materials may also be used to ~orm gasket 40 so long as the material is compliant and compatible with adhesives used to bond panel 22 in the opening. According to one embodiment, gasket 40 may be extruded as a substantially continuous, elongated, strip, striny or strand. For example, one possible extrucled cross section of gasket 40, as seen in Fig. 2A, includes a substantially tubular body 42 having a 2~38(~

concentric inner chamber ~4 forméd by inner wall 46. At least one securing flange 48 extends from tubular body ~2 so that a bonding surrace .~u lS tangent to the exterior surface of tubul2r body 44. A second securing flange 45 may extencl from the opposite side up tubu:lar body ~2 co planar with securing flange 48. The bondinq surface of flange 4~ may also be tangential to tubular body 42. The width and thiclcnesses of securinq ~langes ~8, 49 may vary depending upon the desired bondiny area ancl particular application.
It is anticipated that a width of several centimeters will be suitable ~or most vehicular window applications, while the size and thickness of tubular body 42 will vary depending upon the sealing force necessary in the vehicle after installation along a ~iven portion o~ the yasket.
One of the many possible cross sections of molded gasket 4ûà, shown in Fig. 2B, includes a generally rectangular body 42a which has one surface 5ûa adapted to be adhered to surface 24a of sheet 22a having frit layer 38a.
If desired, rectangular body 42a may be molded about and retain mounting hardware 47a such as locating or mounting studs, clips, and the like, and adapted to retain panel assembly 20a in the vehicle opening. Gasket 40a may also include a lip 48a which extends from rectangular body ~2a and bridge or otherwise close gap 51a betwesn panel peripheral edge 28a and the vehicle body. As in the embcdiment shown in Fig. 2A and described above, the width of rectangular body 42a and the thickness of lip 48a may vary depending upon the desired bonding area and particular application. Gasket ~Oa may be molded using conventional molding techniques such as injection molding, blow molding, pour molding, and the like. Advantages provided by molded 3 ~
gaskets include the ~orming o~ a continuou~ gasket with variable cross section suited for speci~ic applications and the encapsulation o~ mounting stl.lds, clips, and tne liKe, ~o retain the panel in the o~enin(3.
Referring now to Figs. 3A-3L, one method of makiny panel assembly 20 includes obtaining a panel such as previously cut and shaped transparent sh~et-like pansl 22 having the desired size and geomekry adapted to ~it within vehicle opening 30 (Fig. 1). Sheet 22 may have one or more peripheral areas of surfaces 24, 2~ cleaned with a solvent such as methyle~hylketone to remove oils, dirt or other debris which may interfere with the bonding process. After the optional cleaning, at least one coating of primer material 60 is applied to one or both of surfaces 24 or 26, or to frit layer 38 (Fig. 2A), to prepare the panel or frit surface to receive gasket 40. The primer is selected to enhance the adhesion/bond between gasket 40 and sheet surface areas 24, 26 or frit layer 3~ and may be any of several varieties depending on the material of gasket 40 and sheet 22, such as heat and/or pressure activated compositions. The primer may be applied by bxush, pad, roller or spray and allowed to wholly or partially dry to obtain a substantially uniform, even coating to the sheet surface. For panels having the ceramic frit layer, the primer may be applied directly thereto to achieve substantially the same results for preparing the surface for bonding. If gasket 40 is made from a polyvinyl chloride material, a preferred primer is sold under the designation A-1100-~ çombined with an adhesion promoter designated A-1167-B, both produced by B. F. Goodrich Co. of Akron, Ohio.
_9_ ~ .

2~5'~0 Ge~le~ally simultall~ously with the preparation oE
sheet 22, gasket 40 (Fig. 3F) is loadecl in a flxture 62 having a channel 64 corresponding ln shape to the exterior surface o~ body 4~ ~nd adapted to retain gasket 40. The bonding surfaces of cJasket 40 adapted to be adhered to panel ~2 extend above upper surface 65 of fixture 62 in order to make contact with sheet 2~. Channel 64 is in a pattern corresponding to the pattern gasket ~0 to be attached to sheet 22. The gasket pattern may be a complete or continuous loop outl.ining the sheet periphery, a straight or curved shape partially outlining the sheet periphery, or numerous other shapes or patterns adapted to match the requirements for the particular vehicle window opening.
If the pattern of gasket 40 is such that it forms a loop, and the gasket material is in the form o~ an extruded strip, ends 66 may be trimmed at matching angles (Fig. 3G) using a hot wire or similar technique. After the trimming of the gasket ends, the hot ends may be joined to form seam 67 (~ig. 3H). On the other hand, if the gasket - pattern is other than a continuous loop, the extruded strip need only be laid in the fixture pattern, terminating the ends in an appropriate manner. In the case of the tubular gasket shown in Fig. 2A, the joining of gasket ends 66 may hermetically seal inner chamber 4~, trapping a volume of gas therein, thus rendering gasket 40 quite resilient. If the ends are not joined, each end 66 may be pinched closed in order to achieve the same results. In another embodiment, the gasket may be ex-truded and preformed to a specific shape by a secondary operation haviny the ends joined prior to being located in fixture 65. In either case, extruded yasket 40 may include one or more perforations or vents (not 2D~3~a shown) extending throu~h body 42 and joining chamber 44, thus makiny gasket 40 more complian-t. Gasket 40, in such case, l~etain~ u~ular shape ~ased upon the inherent memory of the material from which it is made. Moreover, although gasket 40 is shown to have securirlg flanges 48, 49 and body ~? having substantially the sam2 thickness, it may be made such that walls of body 42 have a difEerent or gradational thic]cness about its circumference, or that securing flanyes 48, 4~ are of d:Lfferent thickness or width.
In addition, yasket 40 may include locating pins, mounting studs of clips, or other hardware accessories fixed therein, depending upon the desired application.
I~ gasket 40 is formed from molded material, some of the same principlas described above may apply, depending upon the desired shape. ~or example, if gasket 40 is molded in a strip and is to be joined to form a loop, the ends may be joined, as described above. However, it ls pre~erred that gasket 40 be molded in the desired shape to be attached to the panel. In this manner~ the extra step of mending or welding together of the ends of the gasket material to complete the loop is removed. If a molded yasket 40 is to be placed around only a portion of panel 22, it may be molded to that particular shape, or a section o~ a looped gasket may be removed to obtain the desired configuration.
The benefits of molding gasket 40 include encapsulation of mounting hardware such as location studs, mounting studs or clips, and the like, within the gasket material. Another advantage is that the corners and bends are preshaped and need little if no stretching to fit in fixture 62~
Af~er forming gasket 40 using one of the two extrusion methods or by molding, and locating gasket 40 in 3 ~ a fixture 62 so as to expose the bonding surface 50, yasket 40 is ready to be adhered to sheet 22. With reference ayain to the example or extruded qasket 40, shown in Figs. 3A-3L, prepared sheet 22 is located on gasket 40 such that primed surface 24 engages bonding surfacets) 50 of securing flange 48, 49 and tubular body 42 (Flg. 3I). Sheet 22 is properly located with gasket 40 by sheet locater pins 82 (Fig. 5) extending substantially perpendicular from fixture 62. The sheet is then pressed into intimate contact with bonding '- surface 50 (Fig. 3J) . Locater pins ~2 are situated to engage peripheral edge 28 of sheet 22 so that sheet 22 may nest therein in only one particular configuration. The force used to press sheet 22 against gasket 40 may range between 7 and 100 pounds per square inch (psi), depending upon the width of bonding surface 50, the length of gasket 40 to be fixed to sheet 22, the temperature of gasket 40 and~or sheet 22, the nature of the adhesive and gasket material, and the geometry of sheet 22. For the latter characteristic, the amount of force may vary along sheet 22 for complex sheet geometries.
Generally simultaneously with the application of the pressure, heat energy is applied to the interface between sheet 22 and gasket 40 by heating frit layer 38 (Fiy. 2A) between sheet 22 and bonding surface 50 of gasket 40 to between 100 and 350 F. (Fig~ 3K). It is preferred that both pressure and heat be applied for between three and thirty seconds in order that heating of frit layer 38 activate primer 60 to bond gasket surface 50 with frit layer 38 and/or panel 22, providing a secure adhesion of gasket 40 to sheet 22. Following the application of pressure and heat for the prescribed period of time, the finished panel 2~9~380 . 1 assembly 20 is allowed to cool before beiny moved from fixture 62 (Fig. 3L).
The above method may ~)e carried out with a fix-ture 62 retained within an apparatus 70, such as shown in Figs.
4A-~G. Device 7n may include a platen 72, spaced directly opposite an assembly 74, housing an extensible foot 76 and a heat energy source 80. Both foot 76 and source 80 may be moved with respect to platen 72. Fixture 62 and platen ~2 may include a heat source (not shown) to preheat gasket 40 lo to at lea~t 100 degree~ F~hrenhelt (F) once loaded thereln.
Several techniques may be used to hold gasket 40 in ~ixture 62, such as undercuts in the gasket channel, and/or projections defined along the flexible, resilient gasket which are then adapted to snap into corresponding recesses in the fixture. Alternatively, a vacuum may be used to retain the gasket. It should be understood that platen 72 may be adapted to receive many different fixtures 62, each having one or more channel patterns to retain gasket ~0.
Each fixture may be readily removed and replaced with another, depending upon the desired application. For example, as seen in Fiy. 5, fixture 62 retains gasket 40 wherein two legs 40a and 40b form a right angle. A third leg 40c interconnects legs 40a, 40b, forming an arcuate hypotenuse.
With sheet 22 located on gasket 40, sheet 22 is urged against securing flange 48. This may be accomplished mechanically by foot 76 disposed at the end o~ a ram 82 integral with assembly 74 (Fig. 4C). Foot 76 is adapted to engage sheet 22, having a plan form to fit within locator pins 82 and inboard of the gasket outline. It is preferred that foot 76 not conceal gasket 40 when engaging sheet 22, 3 ~ ~

but extend only to the ir.side edge o~ the outline to apply a pressure between 7 and 100 psi opposite yasket 40.
Generally simultaneol.lsly with the extension of foot 76, he~t energy source 80 is posi.tioned by ram 82 (Fig.
4D) to a predetermined distance away from sheet 2~. Souxce 80 may be moved using one or more rams similar to 82, or the like. It is preferred that source 80 be a controlled focused source o, radiation (CFIR) 110, such as shown in Fig. 8. Controlled focused infrared source 110 includes one or more infrared emitter a.ssemblies 112 such as Model 5305-104 produced by Radiant ~nergy Research, Inc. of Minneapolis, Minnesota. Emitter 112 may be positioned with respect to sheet 22 in a pattern conforminy to that region of sheet 22 adapted to receive gasket 40 (Fig. 6). In the alternative, a single infrared emitter assembly 112 may be moved above sheet 22 in a pattern conforming to that of the gasket layout by a guided robotic arm or other mechanisms such as a cam-operated guide. Computer/process controller 114 preferably causes infrared emitter assembly 112 to emit infrared energy having a wavelength between 7.0 x 103 and 4.0 x 104 Angstroms into sheet 22 from a side opposite that containing primer 60 and frit layer 38 to heat the interface or frit layer 38 between the sheet and the gasket. A
spectrophotometer 116, disposed above sheet 22 and coupled to aomputer/process controller 114, dstects the energy rsflected and radiated from sheet 22. Based upon the feedback from spectrophotometer 116, controller 114 adjusts the power of infrared energy emitted by assembly 112 such that most of tlle enexgy is absorbed by frit layer 38 in the area of primer 60 to raise ths temperature to the desired level. Although CFIR 110 has been described for use in both ~s~

. 1 preheating and heating after location with the gasket, i.t is contemplated that CF.IR 110 will be mos-t ef~ective to heat ~rit layer 38 after panel 2~ is loccl~ed ~ respec~ c~
yasket 40.
In an alternate embodiment, a controlled area source il8 of infrared radiation (CAIR, Fi.g. 9) is located at a predetermined distance above shaet 22. Controlled area infrared source 118 may include one or more infrared emitters 1~0 such as Model FB122425B3 made by Cassso-Solar Corp. of Pomona, New York. The energy of radiation generated by emitter 120, having a wavelength between the range of 2.7 x 104 and 4.0 x 104 Angstroms, is controlled by computer/process controller 122 based upon input from a ; thermocouple 124 attached to emitter 120, and a spectro-photometer 126 angularly disposed with respect to sheet 22.
A reflector 128 may be disposed beneath sheet 22 to redirect energy back into sheet 22. The CAIR is better adapted to simultaneously heat an exposed area on sheet and may be used ; to preheat the panel, if desired. Contemplated in both of the heating options described above, but shown only in Fig.
9, is a plenum 130 and exhaust fan 132, cooperating to vent : fumes driven off during the heating process.
Since the radiation produced by emitters 110, 118 may be introduced into sheet 22 from a side opposite that contain~ng primer coating 60, it is preferred that sheet 22 have a high transmissivity to the wavelength of radiation selected. Em:itters 110, 118 both produce ~nfrared radiation having a wavelength greater than 7.0 x 103 Angstroms. The transmissivity of the radiation is greatly affected by the particular characteristics of sheet 22. For example, optically clear glass panels have a higher transmissivity 5 ~ ~ ~

(ratio of radiation transmittecl through the panel to that of radiation incident upon the panel) ~or infrared radiation tl.ai; clear non~glass panels because a certain amour~t O~ tile radiation i~ absorbed by the atomic lattlce com~rising the non-glass sheet. Tinted or opaque panels may have a lower transmi,sivity since ~he pigmerl-ts or coloration withjn the material may absorb a portion o~ thQ radiation. For materials having lower transmissivities, it is preferred to select wavelenyths of radiation which promulgate better through the tinted or opaque materials, yet are absorbed at the contact boundary or ~rit layer between sheet 22 and primer coating 60, such as in the range of 5.0 x 103 and 4.0 x 104 Angstroms. In the preferred embodiment of this invention, sheets 22 are optically clear glass sheets and may be single sheet or laminated sheets, depending on the desired function in the vehicle.
In order to reduce problems associated with heating and cooling large expanses of glass or plastic ~
panels, it is preferred that each o~ the above radiation sources direct its energy to a restricted portion of panel or sheet 22. For example, since it is desired to heat only that portion of sheet 22 adapted to engage gasket 40, CFIR
110 or CAIR 118 may be adapted so that the radiation is applied only to the peripheral margin or other location receiving the gasket. Alternatively, a single source may be moved around sheet 22 by a guided robotic arm, as mentioned above. Moreover, one or more emitters may be recessed within a tool patterned to coincide with the area o~ the panel to be heated. In an alternative to energy sources 110 and 118 described above, sheet 22, frit layer 38 and primer 2n~380 . 1 60 may be heated using convection, conduction, induction, radiation, resistive and microwave energy heat sources.
n an alternate embo~iment of the above method shown in Fiy. 7, the forcing o~ sheet 22 against gasker. 40 may be accomplished by creating a negative pressure or vacuum within a chamber ~0 formecl by the inside perimeter g2 of closed-loop gasket ~0, upper surface 65 of fixture 62, and surface 24 of sheet 22. Suction lines, such as 34 extending through platen 72 and fixture 62, are coupled to a vacuum source (not shown) adapted to create a negative pressure ranging between one-halE and five atmospheres (-7 and -70 psi). The vacuum created in chamber 90 draws sheet 22 toward fixture 62 and against gasket 40. Another method better adapted for use with gasket patterns which are not closed-loop is by creating a vacuum between suction cups (not shown) at the ends of vacuum lines 94 within cavity 90.
Although the above descxiption has been madè with reEerence to sheet 22 being moved with respect ko gasket 40, it should be understood that gasket 40 may be moved as supported in a fixture with respect to sheet 22 in the bonding process. Moreover, the amount of pressure required to optimize the contact between panel 22 and gasket 40 is dependent upon several factors, including the total surface area to be bonded, the temperature, size and geometric shape .of sheet 22, and the exact nature and temperature of the adhesive and the material forming gasket 40. For example, for a substantially flat glass sheet 4 millimeters thick, a surface area o:E approximately 1 square meter, and a PVC
gasket having a 2.5 centimeter wide bonding surface extendin~ subst:antially around the entire perimeter of the sheet in a closed loop, the pressure required to effect a 2~3~

secure bond is betweerl about 0.5 and 3 atmospheres (7 to 45 psi) .
ln ad~ition to the steps outlined above, it is preferred to prehèat sheet 22 and gasket 40 before bondiny the two togetheL. In one embodiment, sheet 22 is primed in the desired areas and preheated to drive off any remaining carrier/solvents and raise the temperature of suxrace 24 and frit layer 38. A preferrsd method of heating sheet 22 is irradiating sheet 22 with infrared radi.ation produced by CAIR 118, described above and shown in Fig. 9. Once sheet 22 is preheated (100 F to 350' F), gasket 40 ls bonded to sheet 22 by reheating the frit layer 38 between sheet 22 and gasket 40 to between 100~ and 350 F to activate primer ~0.
Preferably, heating the contact surface between sheet 22 and gasket 40 is accomplished by CYI~ source 110 (Fig. 8) focused on frit layer 38 to heat bonding surface 50 and primer 60 from a side of sheet 22 opposite that of gasket 40, as described above. Sheet 22 is substantially transparent to the infrared radiation (less than 4.0 x 104 Angstroms) passing therethrough and impinging upon the contact surface between gasket 40 and sheet 22. Pressure is also applied, either prior to or simultaneously with the heating, in order to maximize the surface area of each component in contact with the other. After approximately three to thirty seconds of applying pressure and heat, both are removed and assembly 20 is allowed to cool, curing or hardening the bond between gasket 40 and sheet 22. Once assembly 20 is cooled, it may be moved on in the assembly process as finished goods.
Because the heating sources described above with reference to Figs. 8 and 9 are adapted to heat sheet 22 and 2n9~380 fri-t layer 38, gasket 40 is preferred to be heated using a separate heating source. Gasket 40 can also be heated by built-in heaters in the fixture. Gasket 40, made from PVC
or similar polymeric material, may be quite stlff before being loaded into fixture 62~ In order to make gasket ~0 ~nore flexible and promota adhesion, it is preerred that gas~et 40 be preheated to raise the temperature level Oe gasket 40 ~o app-oximatbly 100 F. At that temperature, gasket 40 becomes ~ubstantially pliable and may readily be stretched if necessary to make appropriate curves or bends in the gasket layout.
Following the above steps, a substantially flat sheet of glass having a thickness of 4 millimeters, and a flat layer, was primed with A-lloO-B and A-1167-B primer mixture. A gasket, such as shown in Fig. 2B, was preformed separate from sheet 22 using injection molding technique~ in a 250 ton press using 200 tons of clamping pressure. The melt temperature of the gasket material was 380 F and had a nine second cure time in the mold. While the gasket was being formed, the frit layer on the glass panel was pre-heated to approximately 300 F. After the gasket was formed and had cooled to approximately 100 F it was removed from the mold and located in a fixture such that the bonding surface was exposed. The preheated panel was then located -with respect to the gasket and pressed thereon using 14 psi of force maintained for approximately seven seconds.
Simultaneously with the pressure, the frit layer was heated from a side opposite the gasket to activate the primer.
Following the application of heat and pressure, the panel assembly was allowed to sit for less than one minute before being removed from the fixture.

3 ~ ~3 Althouyh in each of the above embodiment~s gasket has been described generally as being made ~rom PVC, other materials may also be used, lncluding reaction injection molded (RIM) urethane or therroplastic ela~tomcrs such as thermoplastic rubber (TPR), thermopla~tic 012fin (TPO~, and thermoplastic urethane (TPU). The preferred materia], PV~, offers se-v-eral advantages, incLuding ease in handlinq, is readi~y ~vaila~le, inexpensive~ and recyclable. Moreover, PVC material is substantially resistant to ultraviolet lo radiation and pliable in a variety of climatic conditions.
A preferred PVC material is 48562 obtained from Vista Chemical Co. of Aberdine, Mississippi. Moreover, the gaskets may be mass produced using any one of the above materials separate to the bonding process.
Figs. 10 and 11 generally illustrata two additional embodiments o~ a panel assembly made in accordance with the method of this invention. Fig. 10 is a fragmentary section view of one embodiment 200 of panel assembly 20 shown in Fig. 1 and taken along lines XI-XI.
Panel assembly 200 includes a panel or sheet 222 which may be tempered, laminated, or otherwise strengthened using conventional principles. Sheet 222 has two opposing surfaces 224, 226 joined at a peripheral edge 228. Surface 224 may include a ceramic or similar material frit layer 238 bonded thereto to conceal the mounting of panel assembly 200 in the opening. Fixed to frit layer 238 and/or surface 224, and extending around at least a portion of sheet 222 near peripheral edge 228 is a flexible, resilient, extruded gasket 240 adapted to locate and seal panel 222 with sheet metal pinch flange 232 forming in the openinq. In this 2 ~ Q

embodiment, panel or sheet 222 may be movable with respect to pinch flange 232.
Gasket 240 lncludes ~I tubular body 242 having a generally concentric inner chal~b2r 24~ formed by wall 246.
Tubular body 242 i3 interconnected by an i~tegral rib or web 243 to a securing flange 248 'naving a bonding surface 250 adapted to contact and bond with sheet 222 and/or frit layer 23~. Also extending from tubular body 242 is a lip 252 adapted to engage the outer surface of sheet metal 254 and drape within opening 256 between sheet metal 254 and peripheral edge 228. This panel assembly 200, satisfying flush-mountsd panel requirements for next gèneration vehicles, preferably has gasket 240 extruded from UV-stable PVC or similar material, as described above.
Fig. 11 generally illustrates in partial cross section one embodiment of a fixed panel assembly 300 made in accordance with the above method. Sheet 322, with or without a frit layer as described above, receives an extruded bulb seal 340 adhered to surface 324 near peripheral edge 328. Seal ox gasket 340 includes a tubular body or bulb 342 having a gas filled chamber 344 defined by wall 346. Extending from bulb 342 generally normal to wall 346 is a securing flange 348 having a securing surface adapted to contact and be adhered to surfaca 324. An opposite side 354 of flange 348 includes a channel 356~
Gasket 340 is bonded to surface 324 of panel 322, as described above, with respect to the general method such that bulb 342 is located between peripheral edge 328 and sheet metal 358 on the vehicle exterior. The panel 322 and gasket 340 are bonded in the opening by a bead of adhesive 360 extruded into channel 356 and pressed against pinch 2~3~

flange 362. The resilient nature of bulb 342 se~ls the yap between the sheet metal and glass with a generally smooth ~ransitio~, ~hich results in reduced wind noise and dirt infiltration ar.d prGvides an aesthe.tica:Lly pleasing appearance. Since a portion of yasket 340 is exposed in the panel opening, it ic pre~erred that gasket 340 be made from UV-stable material such as PVC.
The invention has been descri~ed with respect to specific pre~erred embodiments thereof and many variations and modifications will become apparent to those skilled in the art. For example, the heat activated primer composition may be substituted by a chemically activated adhesive. This is particularly the case for panels made from materials other than glasq such as acrylic or similar polymeric material. It is, therefore, the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.

'~ ' ' :' - , ~

Claims

1.

A product formed according to the method as recited in claim 2.

A product formed according to the method as recited in claim 6.

A product formed according to the method as recited in claim 8.

A product formed according to the method as recited in claim 10.

A product formed according to the method as recited in claim 13.

A product formed according to the method as recited in claim 14.

A panel assembly, comprising:
a sheet-like panel having first and second surfaces terminating in a peripheral edge;
a primer coating applied to at least one of said surfaces;
a gasket, formed separately from said panel, and bonded to said at least one surface having said primer coating by the application of heat and pressure exerted upon the contact boundary between said panel and said gasket.

A panel assembly as recited in claim 64, wherein said gasket includes:
a gas filled body; and at least one securing flange extending from said tubular body to define a bonding surface engaged with said at least one surface.

A panel assembly as recited in claim 64, wherein said gasket includes a lip seal extending from said gasket beyond said peripheral edge of said panel.

A panel assembly as recited in claim 65, wherein said gasket includes a lip seal extending therefrom and beyond said peripheral edge of said panel.

A panel assembly as recited in claim 65, wherein said gas filled body is disposed outboard of the peripheral edge of said panel.

A panel assembly for use in a vehicle opening, comprising:
a sheet-like panel of size and geometry adapted to fit in the vehicle opening, said panel having a first and second surfaces terminating in a common peripheral edge;
heat activated bonding means on a portion of said first panel surface proximate said peripheral edge; and a polymeric gasket formed separately from said sheet-like panel and having a bonding surface engaging said heat activated bonding means on said portion of said first panel surface.

A panel assembly as recited in claim 69, wherein said heat activated bonding means is a primer composition on said portion of said first panel surface.

A panel assembly as recited in claim 69, wherein said gasket is formed from polyvinyl chloride.

A panel assembly as recited in claim 69, wherein said sheet-like panel is a window.