Window Surround Module

• US 20080127569A1
• Filed: 01/18/2006
• Published: 06/05/2008
• Est. Priority Date: 01/18/2005
• Status: Active Grant

• Current Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Original Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Inventors: Boddy, Ian, Ellis, Peter John
• Granted Patent: US 8,037,640 B2
• Time in Patent Office: Days
• US Class Current: 49/502
• CPC Class Codes: B60J 5/0402 window frame details, including sash guides and glass runs
• CPC Class Codes: B60J 5/0404 Outside rear view mirror support
• CPC Class Codes: B60J 5/0406 window frame formed separately as module

Abstract

A window surround module (10) for installation to the perimeter of a window opening (120, 248) in a motor vehicle door panel (118 , 244) comprises individual window surround components that are fabricated into a unitary structure. The individual components include two or more of a header molding (16, 130), a bell molding (18, 132), a mirror base (12, 28, 140), a B-pillar trim piece (14, 134), a glass run channel (150, 260), a wire harness (264), a wire harness support (262), seals (24, 200, 202, 2004), a mirror (30, 114), and a window (122, 246). At least some of the components are molded together to form a unit to which other components are mounted.

Claims

1. A window surround module for installation to the perimeter of a window opening in a motor vehicle door panel, comprising:

a prefabricated assembly of a header molding, a belt molding, a mirror base, and a glass run channel wherein at least two of the header molding, belt molding, mirror base, and glass run channel are made at least partly of thermoplastic, and formed together as a unit,

whereby the window surround module can be installed to a motor vehicle door panel as a unitary structure.

2. The window surround module of claim 1, wherein the unit comprises a mirror base and a glass run channel injection molded together.

3. The window surround module of claim 2 wherein the unit is a first unit and the header molding and belt molding are injection molded together as a second unit, and the first unit and the second unit are co-molded together.

4. The window surround module of claim 1 wherein the header molding, belt molding, mirror base, and glass run channel are made at least partly of thermoplastic, and formed together as a unit.

5. The window surround module of claim 1 wherein the prefabricated assembly includes a B-pillar trim piece.

6. The window surround module of claim 1 wherein the prefabricated assembly includes window glass mounted to the glass run channel.

7. The window surround module of claim 1 wherein the prefabricated assembly includes a mirror mounted to the mirror base.

8. The window surround module of claim 1 wherein the prefabricated assembly includes wiring mounted to the glass run channel.

9. The window surround module of claim 8 wherein the wiring is mounted to the glass run channel by clips.

10. The window surround module of claim 8 wherein the glass run channel has a wiring channel and wiring is mounted to the wiring channel.

11. The window surround module of claim 10 wherein the wiring channel is integrally formed with the glass run channel.

12. The window surround module of claim 2 wherein the header molding and belt molding are mechanically secured to the unit.

13. The window surround module of claim 1, and further comprising a rear quarter window.

14. A method of fabricating a window surround module for installation to the perimeter of a window opening in a motor vehicle door panel, comprising:

providing a mold for molding at least two of a header molding, a belt molding, a mirror base, and a glass run channel;

molding a thermoplastic material in the mold to form at least two of the header molding, the belt molding, the mirror base, and the glass run channel together as a unit;

removing the unit from the mold after the thermoplastic material has hardened; and

mounting to the unit the components of the header molding, the belt molding, the mirror base, and the glass run channel not molded in the mold to form a unitary structure for later installation to the perimeter of a window opening in a motor vehicle door panel.

15. The method of claim 14 wherein at least three of the header molding, the belt molding, the mirror base, and the glass run channel are molded in the mold.

16. The method of claim 14 wherein all of the header molding, the belt molding, the mirror base, and the glass run channel are molded in the mold.

17. The method of claim 14 wherein the molding step comprises injection molding.

18. The method of claim 14 further comprising the step of mounting to the unit any of a mirror, a seal, and a window as part of the unitary structure.

19. The method of claim 14, wherein at least one of the header molding, the belt molding, the mirror base, and the glass run channel is made at least partly of a first thermoplastic material having a first melting temperature, and at least one other of the header molding, the belt molding, the mirror base, and the glass run channel is made at least partly of a second thermoplastic material having a second melting temperature.

20. The method of claim 14, wherein at least two of the header molding, the belt molding, the mirror base, and the glass run channel are molded together as a first unit in a first molding step, at least two other of the header molding, the belt molding, the mirror base, and the glass run channel are molded together as a second unit in a second molding step, and the first and second units are molded together to form the unitary structure.

21. The method of claim 20, comprising the step of cooling the at least one component made of a first melting temperature in the mold during the molding of the at least one other component having a second melting temperature.

22. The method of claim 14, further comprising incorporating a rear quarter window into the unitary structure.

23. The method of claim 14, further comprising incorporating a B-pillar trim piece into the unitary structure.

24. The method of claim 14, further comprising forming a wire harness support structure along the glass run channel for supporting a wire harness extending from the mirror base.

25. The method of claim 24, wherein the wire harness support structure is a conduit extending longitudinally through the glass run channel.

26. The method of claim 24, wherein the wire harness support structure comprises at least one clip for holding the wire harness along the glass run channel.

27. The method of claim 21, wherein the portion of the mold to be cooled is provided with a conduit for carrying a coolant in fluid communication with a refrigeration system.