阅读说明：本技术 车门模块 (Vehicle door module ) 是由 布莱恩·H·斯塔斯 阿什利·辛普森 莉萨·霍普曼 托马斯·查尔斯·西布兰迪 于 2018-11-09 设计创作，主要内容包括：车门模块包括一体式框架和由该一体式框架限定的区域,其中限定区域填充有包含闭孔聚合物泡沫的材料。车门模块可以通过包覆成型或压缩成型制成。(The door module includes a unitary frame and a region defined by the unitary frame, wherein the defined region is filled with a material comprising a closed cell polymer foam. The door module may be made by overmolding or compression molding.)

1. A door module comprising a unitary frame and a region defined by the unitary frame, wherein the defined region is filled with a material comprising a closed cell polymer foam.

2. The door module of claim 1 wherein the unitary frame comprises polypropylene and fiberglass.

3. The door module of claim 1 or 2, wherein the glass fiber is present in an amount of 25 to 40 wt.% based on the total weight of the integrated frame.

4. The door module of any of claims 1-3, wherein the closed cell polymer foam comprises a thermoplastic elastomer.

5. The door module of any of the preceding claims, wherein the closed cell polymer foam comprises a polyurethane foam.

6. The door module of any of the preceding claims, further comprising a perimeter seal.

7. The door module of claim 6 wherein said perimeter seal comprises the same closed cell polymer foam as said defined area.

8. The door module of any of the preceding claims, further comprising a foam bridge for connecting the defined area filled with a material comprising a closed cell polymer foam.

9. The door module of any of the preceding claims, further comprising an adhesive disposed between a portion of the unitary frame and a portion of the closed cell polymer foam.

10. The door module of any of the preceding claims, wherein the defined area is filled with a material consisting essentially of a closed cell polymer foam.

11. A method of manufacturing a door module includes overmolding a unitary frame having a defined area that is open with a closed cell polymer foam, thereby filling the defined open area with a closed cell polymer foam.

12. The method of claim 11, wherein the unitary frame comprises polypropylene and fiberglass and the closed cell polymer foam comprises a thermoplastic elastomer.

13. The method of claim 11 or 12, further comprising surface treating the unitary frame prior to overmolding.

14. The method of any of claims 11-13, wherein the unitary frame is formed and overmolded in a single tool.

15. The method of any of claims 11-14, wherein the unitary frame comprises polypropylene and fiberglass.

16. The method of any of claims 11-15, wherein the closed cell polymeric foam comprises a thermoplastic elastomer.

17. The method of any of claims 11-15, wherein the closed cell polymer foam comprises a polyurethane foam.

18. A method of manufacturing a door module includes overmolding a closed cell polymer foam with a unitary frame having a defined area to produce a unitary frame having a defined area filled with a closed cell polymer foam.

19. The method of claim 18, wherein the unitary frame comprises polypropylene and fiberglass and the closed cell polymer foam comprises a thermoplastic elastomer.

20. The method of claim 18 or 19, wherein the closed cell polymer foam is formed and overmolded in a single tool.

Background

The door module is part of an integrated door assembly. The door module has accessories for many components, such as window regulators, speakers, and wiring harnesses. The door module provides sufficient structural strength to support these components and to support the function of these components.

Previously, door modules were formed of metal, plastic, or a combination thereof. As the need to reduce the overall weight of the vehicle increases, and the need to reduce the weight of all vehicle components while maintaining the same functionality increases. It is therefore desirable to obtain a door module having a reduced weight compared to previous door modules.

Brief description of the drawings

Disclosed herein is a door module that includes a unitary frame and a region defined by the unitary frame, wherein the defined region is filled with a material comprising a closed cell polymer foam. In some embodiments, the defined area is filled with a material consisting essentially of a closed cell polymer foam.

A method of manufacturing the door module described above is also disclosed herein. The method includes overmolding a unitary frame having an open defined area with a closed cell polymer foam to fill the defined open area with a closed cell polymer foam.

Alternatively, a method of making the door module described above includes overmolding a closed cell polymer foam with a one-piece frame having defined areas to produce the one-piece frame having defined areas filled with the closed cell polymer foam.

It is also contemplated that the method of manufacturing the door module may include compression molding the closed cell polymer foam with the unitary frame.

Brief description of the drawings

The following description should not be considered limiting in any way. Referring to the drawings, like elements are numbered alike:

FIG. 1 illustrates a one-piece frame of a door module having an open defined area.

Fig. 2 and 3 depict a one-piece frame with defined areas filled.

Detailed Description

A detailed description of one or more embodiments of the disclosed apparatus and method is given herein by way of illustration and not limitation.

The door module described herein has an integral frame that provides structural strength to the door module. The unitary frame defines a region filled with a material comprising a closed cell polymer foam. In some embodiments, the unitary frame defines a region filled with a material consisting essentially of a closed cell polymer foam. In this context "consisting essentially of" allows for the inclusion of stabilizers, colorants, and similar additives, but excludes unfoamed thermoplastic materials.

Fig. 1 shows a one-piece frame 10 having a defined area 20. The unitary frame also has through holes 22 for attachment of the rest of the door assembly and locations 24 for audio speakers. Fig. 1 shows the window regulator 26 having an integrated rail, however, it is also contemplated that any window regulator system may be used.

Fig. 2 shows the one-piece frame 10 with the fill definition area 30. The fill definition zone 30 is comprised primarily of closed cell polymer foam. The closed cell polymer foam may uniformly fill a defined area, or may include a relieved area or relief to accommodate a protrusion from another portion of the door assembly. The door module may preferably include a peripheral seal 40. The perimeter door seal may comprise a closed cell polymer foam that is the same as or different from the closed cell polymer foam used in filling the confined area. The cross-section of the perimeter seal may be compressive or curved in design. As shown in fig. 3, different regions of the polymer foam may be connected by foam bridges 50. In embodiments, the foam is overmolded, which may improve material flow and reduce the total number of injection points. In embodiments where the foam is a thermoformed or compression molded sheet adhered to the unitary frame 10, these bridges allow for improved relative positioning of the different cell foam portions.

The unitary frame comprises an unfoamed polymeric composition. The unfoamed polymer composition may further comprise a reinforcing filler. Exemplary non-foamed polymeric materials include thermoplastics such as polyethylene, polypropylene, polyethylene-polypropylene copolymers, polyamides, polyamide/polyphenylene ether blends, and combinations thereof. Exemplary reinforcing fillers include glass fibers, carbon fibrils, wollastonite, and combinations thereof. The glass fibers and carbon fibers may be continuous in woven form or may be discontinuous chopped fibers. When present, the reinforcing filler may be used in an amount of 10 to 60 or 25 to 40 weight percent relative to the total weight of the unitary frame.

Closed cell polymeric foams may be thermoset or thermoplastic. Exemplary thermosets include one-part or two-part polyurethane foams. Exemplary thermoplastics include thermoplastic elastomers (TPEs) and silicones. The closed cell polymeric foam may have a thickness of 0.5 to 5 mils (0.0127 to 0.127 mm). In some embodiments, the closed cell foam in the peripheral seal has a hardness value (shore a) of 3 to 80, as determined according to astm d 2240. Within this range, it is contemplated that the shore a value of the perimeter seal material can be 3 to 30 when the cross-section of the perimeter seal is compressible in design. Also within this range, it is contemplated that the shore a value of the perimeter seal material is 40 to 80 when the cross-section of the perimeter seal is curved in design.

Adhesion between the unitary frame and the closed cell polymeric foam may be facilitated or provided through the use of an adhesive material, a compatibilizing interlayer, or a surface treatment. Exemplary surface treatments include flame treatment and plasma treatment. Exemplary adhesives include acrylic-based adhesives. Exemplary compatibilizing interlayers include polymers known to be compatible with the monomer framework and the closed cell polymer foam. For example, when the unitary frame comprises polypropylene and the closed cell polymeric foam comprises polystyrene, the compatibilizing intermediate layer may comprise a polypropylene-polystyrene copolymer. In some embodiments, the unfoamed polymer composition and the closed cell polymer foam are compatible and do not require adhesive materials, compatibilizing interlayers, or surface treatments. For example, when the unitary frame comprises polyamide and the closed cell polymeric foam comprises urethane, no adhesive material, compatibilizing interlayers, or surface treatments are required. Similarly, when the unitary frame comprises polypropylene and the closed cell polymer foam comprises a thermoplastic elastomer, no adhesive material, compatibilizing interlayers, or surface treatments are required.

The door module may be made by first forming a unitary frame and then overmolding a closed cell polymer foam. The integral frame and subsequent overmolding may be performed in the same tool or in separate tools as desired. If desired, the integrated frame may be surface treated or coated with an adhesive to promote adhesion.

Alternatively, a closed cell polymer foam may be placed in the tool and the unitary frame overmolded onto the foam. The closed cell polymer foam may be coated with or impregnated with an adhesive to promote adhesion to the unitary frame. It is also contemplated that the closed cell polymer foam may be formed in the same tool used to mold the unitary frame.

In a third method, a closed cell polymer foam is compression molded with a unitary frame. In this method, a closed cell polymer foam and an integral frame are placed in a tool and compression molded.

In any of the foregoing methods, the molding temperature, time, and pressure will be determined by the materials used, and can be determined by one skilled in the art.

In any of the foregoing methods, the foam used in the perimeter seal may be the same or different than the defined area. It is also contemplated that when the closed cell polymer foam is overmolded onto the unitary frame and the perimeter seal is of a different material than the defined area, the overmolding may be sequential. When performed sequentially, the two overmolding steps may be performed in the same tool or in separate tools.