Window surround module

• US 8,037,640 B2
• Filed: 01/18/2006
• Issued: 10/18/2011
• 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
• Primary Examiner(s): REDMAN, JERRY E
• Application Number:
  US11/814,255
• Publication Number:
  US 20080127569A1
• Time in Patent Office: 2,099 Days
• Field of Search: 495/02, 495/06, 296/146.1, 296/146.5
• US Class Current: 49/506
• 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 method of fabricating a window surround module, including a header molding, a belt molding, a glass run channel, and a mirror base, for installation around a window opening in a motor vehicle door panel utilizing a mold assembly having a mold section including a cooling surface, the method comprising the steps of:

molding the header molding and belt molding using a thermoplastic material having a first melting temperature;

cooling the cooling surface associated with the formation of the header molding and the belt molding;

molding the mirror base and the glass run channel using a thermoplastic material having a second melting temperature greater than the first melting temperature;

maintaining the header molding and belt molding at a temperature below the first melting temperature while the thermoplastic material for the mirror base and the glass run channel is heated to the second melting temperature; and

removing the window surround module from the mold.

2. The method of claim 1 wherein the window surround module includes a window glass mounted to the glass run channel.

3. The method of claim 1, further comprising incorporating a rear quarter window into the window surround module.

4. The method of claim 1, further comprising incorporating a B-pillar trim piece into the window surround module.

5. The method of claim 1, further comprising forming a wire harness support structure along the glass run channel for supporting a wire harness extending from the mirror base.

6. The method of claim 5, wherein the wire harness support structure is a conduit extending longitudinally through the glass run channel.

7. The method of claim 5, wherein the wire harness support structure comprises at least one clip for holding the wire harness along the glass run channel.

8. The method of claim 1 wherein the step of cooling the cooling surface associated with the formation of the header molding and the belt molding includes the step of delivering coolant to the cooling surface via a coolant supply conduit.