CA1311511C

CA1311511C - Edge guards having non-metallic bodies

Info

Publication number: CA1311511C
Application number: CA000556407A
Authority: CA
Inventors: Robert Adell
Original assignee: Individual
Current assignee: Individual
Priority date: 1987-01-20
Filing date: 1988-01-13
Publication date: 1992-12-15
Anticipated expiration: 2009-12-15
Also published as: GB2201641B; DE3801411A1; GB8800877D0; GB2201641A; DE3801411C2

Abstract

ABSTRACT OF THE DISCLOSURE

A decorative and protective edge guard comprises a non-metallic body having a curved base and legs extending from the base for fitting against sides of an object onto which the edge guard is installed. Various embodiments are disclosed.
In one embodiment, the body contains notch structure formed in its surface and a layer of material having a size corresponding to that of the notch. In another embodiment, the layer covers only one half of the body, leaving the other half uncovered. In other embodiments the base is of reduced thickness compared to the legs. Various forms of layers may be applied to the bodies.

Description

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~DGE GUARDS HAVING_NON-METALLIC soDIEs sackground and Summary of the Invention This mechanical invention relates generally to edge guards, and more particularly it relates to novel edge guards, for use on the edges of objects, such as automobile doors.
When applied to the trailing edge of a door, an edge guard provides not only decoration, but also protection when the trailing edge is swung against another object, not only for the trailing edge of the door, but also for the object which is struck. This is not to say that an edge guard can always protect and withstand substantial impacts, but edge guards are useful in preventing chipping, knicking, scratching and like damage which typically arises in regular everyday use of an automobile, for example the opening and closing of the doors in a confined space such as in a crowded parking lot.
Applicant's prior inventions, which are the subjects of many U.S. patents, generally relate to metallic edge guards, or insulated metallic edge guards. Metal possesses superior decorative and function characteristics, and the insulated metallic edge guards advantageously combine the benefits of metallic and non-metallic components.
Although Applicant continues to prefer the insulated metallic type of edge guard for automotive use because of the combination of benefits which it provides, he has discovered ways to improve upon non-metallic edge guard bodies in several 3~

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ways which can be useful for certain applications. These imprOveMentS in non-metallic edge guard bodies are the subject of this patent application. Although an edge guard that has a non-metallic body may also have a metal foil or film applied to it for decoration, it is still referred to as a non-metallic.
Non-metallic edge guards are not broadly new. Examples exist in prior patents such as U.S. Patent 3,547,516 issued to Shanok et alO on December 15, 1970 and U.S. Patent 4,372,083 issued to ~atzikeuis et al. on February 8, 19~3.
While these prior non-metallic edge guards claim to possess certain beneficial characteristics, the truth is that they are difficult to install, especially on contoured edges, and once installed, they may not retain satisfactorily over the life of the automobile. Moreover, the improved body fit programs of automobile manufacturers in recent years render it difficult to fit the non-metallic edge guards onto the doors without interference with the door frame openings when the doors are closed.
The prese/l-t invention is directed -to new and useful improvements in non-metallic edge guards which render them superior to the prior non-metallic edge guards. These improvements relate -to the ability to give satisfactory fit, retention, decoration and protection. Details of the improvements will be seen in the ensuing description and claims which should be considered with the accompanying drawings. The drawings disclose a preferred embodiment in ~
accordance with the best mode contemplated at the present time in carrying out the invention.

srief Description of the Drawings Figs. 1-22 are longitudinal end views of the non-metallic bodies of different embodiments of edge guards according to the invention.
Figs. 23-44 are longitudinal end views corresponding to Figs. 1-22 of the completed edge ~uards.
Figs. 45-48 are views illustrating a method of making the edge guards.
Fig. 49 is a perspective view illustrating a step in the method, and Fig. 50 is an enlarged sectional view along line 50-50 in Fig. 49.
Fig. 51 is a modified form of Eig. 50.
Fig~ 52 is a view illustrating a representative installation of an edge guard, and Eigs. 53 and 54 are modified orms of edge guards for facilitating installation on contoured edges.
Figs. 55-67 are additional embodiments of edge guards.

Description of the Preferred Embodiment In the several views wherein like reference numerals designate like parts, the edge guard 100 comprises a non-metallic body 102 and a much thinner outer layer 104 applied at least to the exterior of body 102. The body comprises a curved base 106 and leys 108, 110 which extend 1 3 ~

from base 106, thereby giving the edge guard a general U-shaped or ~-shaped cross section which is open in varying degrees as por~rayed by the several drawing figures. Figs.
1-22 show various bodies 102. In some Figs. the legs are of different lengths; in others they are the same length.
The bodies are formed with various notching patterns for reception of layer 104 in various ways. The notching is designated, generally, by the numeral 112 and corresponds in thickness essentially to the thickness of layer 104. In some embodiments, the notching comprises an undercut 114; in others; one or more slots 116; and in stll others, a combination of both. There are various configurations of undercutting and slotting.
In general the undercutting 114 extends along a substantial portion of the outside of at least one of the legs and partially into the base. The slotting in general takes place adjacent the distal end of a leg, on either the interior or the exterior face of the body, and is at an angle to the length of the corresponding leg. Figs. 1-22 show various forms of bodies containing various patterns of undercuts 114 and slots 116.
Figs. 23-44 show the finished edge guards after the layers 104 have been joined to the bodies. The layers fully occupy the zones of notching, and where there are slots into the body, the margins of the layers are inserted into the slots. Hence, layer 104 covers the exterior of the body along ~L 3 ~

at least a portion of the base and a substantial adjoining portion of a leg adjacent the base. The layer also possesses flushness in relation to body 102 in the finished edge guard.
Certain of the embodiments of edge guard bodies have essentially uniform thickness throughout their legs and base.
Fig. 2 is an example. Other embodiments, however, have a reduced thickness base such as Fig. 1, for example. The reduced thickness base is advantageous in securing better conformance and fit especially where the extent of the base exceeds 180, although the reduced thickness base can be useful in embodiments, such as Fig. 22, where the extent of the base is les~ than in Fig. 1. The illustrated shape of reduced thickness bases is advantageous from manufacturing and use standpoints. It invol~es a gradually reducing taper extending from the proximal end of each leg to essentially the mid~point of the base.
Figs. 45-48 show a method of making the edge guards.
The material of body 100 is extruded by a conventional plastic extruder (step 200) in the flat to contain the desired notching pattern. These Figs. 45-48 illustrate making the example of Fig. 36. The layer 104 is joined to the body in fit to the notchin~ pattern so that the two parts 102, 104 become a unit (step 202). Then the unit is formed to the desired shape such as that portrayed by Fig. 48 (step 204).
Preferably adhesive is applied (as a s$ep 208) to the notching before the layer 104 is joined to the body 102 to aid in the ~ 3 ~

joining of the two parts. Since the body is still warm after leaving the extruding step, it is possible that the heat and the characteristics of the respective materials constituting parts 102 and 104 could be suitably joined without the adhesive application step. Likewise it is to be appreciated that the illustrated method, although preferred, is not necessarily the only way to make the finished edge guard. For instance, the body could be extruded directly to the final shape and the layer then applied ~o the finished shape o the body.
Various plastic materials are suitable for the body;
PVC however has certain advantages for certain applications and will probably enjoy the most widespread use. It can be colored to desired colors and can be extruded to different cross sectional shapes with standard equipment containing suitable dies to produce the desired cross section. Moreover, there are adhesives available for use in joining the plastic and the layer 104 and also joining the plastic to an edge of most metallic and/or painted edges onto which the edge guard is installed.
The layer 104 is both decorative and functional. The layer can be made in different colors to match, and or contrast with the color of body 102. The layer also adds a protective character which is not present in the PVC body.
Use of a material such as mylar, or PVF, for the layer 104 provides functional attributes of durability and toughness, ~L 3 ~
yet are compatible for joining with PVC through use of conventional joining processes such as those described above.
Fig. 50 illustrates a PVF layer 104 and Fig. 51 illustrates mylar. The mylar is transparent and contains an encapsulated metallic foil. This enables the edge guard to be endowed with a metallic looking appearance.
Fig. 52 shows an edge guard 100 installed on the edge of an automobile door 300. Where the edge is highly contoured, it may be desirable to impart either a U-shape or a V-shape notching pattern 302, 304 as shown in Figs. 53 and 54 respectively.
The edge guard exhibits the ability to conform to the edge onto which it is installed, but typically lacks the ability to be self-retaining. Consequently, an adhesive is applied to the interior of the body to cover the legs and base so that the entirety of the interior face can be adhered to the edge onto which the edge guard is fitted.
Fig. 55 shows a further embodiment of edge guard that has a general U-shape that is quite similar to Fig. 28.
However, it has a layer 104 covering the exterior of the body only along the outer leg and the adjoining half of the curved base. Thus the body has an undercut for receiving the layer.
It also has slots 116 for reception of the side edges of layer 104, but these slots 116 are quite shallow. In fact, provision for them need not even be incorporated into the extruding die that is used to create the cross section of body \

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102 during its fabrication by an extrusion process. Rather, they can be created in the extruded plastic, before it has fully set, by forcing, or tucking, the side edges of the layer into the still somewhat formable material of the body at the opposite terminations of the undercut 114, as viewed endwise of body 102. Upon body 102 fully setting, the slots 116 that are formed by so embedding the layer's side edges in the body, are able to retain the edges thereby reducing any tendency toward separation and/or delamination.
Various combinations of heat and/or pressure and/or adhesive may be used to join layer 104 to body 102 in the manner described, any particular combination used being primarily a function of the particular materials for layer 104 and body 102.
sy making layer 104 as metal foil that is encapsulated in clear plastic, and disposing it on the exteriGr of the trailing edge of an automobile door, a metallic appearance is presented. Alternately, by disposing the other leg 110 on the exterior of the edge, the color of body 102 is presented.
Hence, the single edge guard is capable of presenting either of two different exterior appearances, yielding a savings over having to make and inventory two different models of edge guard, one fully metallic, the other fully the color of the non-metallic body.
In certain automobiles the leading edge of the rear door will move inwardly as the rear door is swung open, and ~ 3 ~

this inward movement will be accompanied by a small component of forward motion. An edge guard like the embodiments of Figs. 56-60 that is on the rear edge of the front door with leg 108 as the outside leg, is not struck by the leading edge of the rear door as the rear door is swung open. To provide clearance for the rear door swing, the edge guard has a particular shape in the region of where the inside leg 110 merges with the base 106 so that the minimum thickness of the edge guard is along that portion of the base extending from approximately the midpoint of the base, letter M, along about 45 of arc to begin merging into the inner leg. The interior surface of the base is radiused along substantially a common radius R, preferably .070 inch, and the thickness is substantially constant over this region, preferably at .005 inch thickness. seyond 45, the inside surface continues along the .070 inch radius extending preferably slightly beyond 90 to merge tangentially into the straight interior surface of the inner leg; however, from the 45 point, the exterior surface of the base extends from the exterior radius along a tangent T to blend into the straight exterior surface of the inner leg by a small curved radius Rl.
Each leg has a substantially constant thickness, preferably .060 inch, and the distal end is semicircularly shaped to a radius half the nominal thickness, i.e. a .030 inch radius. From the base midpoint to where the base merges into the proximal portion of the outer leg, the thickness 1 3 ~

progressi~ely increases. Between the mid-point of the base and where the base merges into the straight exterior surface of the outer leg, the exterior surface of the base extends along an arc such that for any given angular distance about the center of R, as measured from the midpoint of the base, the thickness of the base toward the outer leg is larger than it is at the same angular distance from the midpoint of the base toward the inner leg.
Fig. 57 shows such an insert layer 104 applied to notch structure 112.
Fig. 5~ shows an embodiment of edge guard that generally has a .060 inch thickness and semi-circular distal ends, except at the region bridging the inner leg and the base. The clearance region for the rear door swing is provided by the flat chamfer surface 60 which extends at 45 from the midpoint of the base to the exterior surface of the inner leg. According to Fig. 58, the thickness of the base progressively decreases from the base midpoint until about the middle of surface 60 and then progressively increases to the inner le~. Thus, the minimum thickness of the base occurs at substantially the middle of chamfer 60. This point of minimum thickness is nominally dimensioned .010 inch plus or minus .005 inch.
Other decorative techniques may be imparted such as that which is portrayed in Fig. 59 in which a layer 104 is applied to notch structure 112. Since the purpose of this ~ 3 ~

construction is to provide a bright decorative appearance on the outer leg simulating a full metallic edge guard, a bare metallic foil or vacuum metalizing could be used as the layer, although the encapsulated foil, previously described, is preferred.
Fig. 60 illustrates yet another embodiment which is similar to Fig. 58 except that a pair of chamfers 60 are provided on both sides of the base in a symmetrical manner.
In Figs. 61-66, the edge guard comprises a notch structure 112 located in the exterior surface and starting at the midpoint of base 106. A layer 104 is applied to extend from the notch structure to along the exterior surface of the base and at least onto the exterior of the outer leg. In Fig.
61, the entire exterior surface of leg 108 is covered, and in fact, the layer extends around the distal end of the leg and fits in a slot 116 on the interior surface.
In Fig. 61, the exterior surface of the inner leg presents the color of the edge guard body itself. The exterior appearance presented by the outer leg is that of the layer provided that the layer is other than strictly transparent. (If the layer were only transparent, the color of the edge guard material would be seen through it.) A
metallic appearance is imparted to the outer leg of the edge guard by constructing the layer by any procedures previously described.
Because of the symmetrical nature of the edge guard of 13111 13 'L ~.
Fig. 61, the same edge guard may be used on both right and left doors. Moreover, by reversing an edge guard such that the inner leg becomes the outer leg and the outer leg becomes the inner leg, the particular coloration of the edge guard body can be presented on the exterior of the door, instead of that of layer 104.
Fig. 62 retains the notch structure starting at the midpoint of the base but which presents another exterior appearance for the outer leg because layer 104 stops short of the leg's distal end.
Fig. 63 illustrates another embodiment similar in appearance to Fig. 62.
Fig. 64 illustrates another embodiment in which no~ch structures are located to start at the midpoint of the exterior of the base but extend to both legs and receive respective layers 104. Assuming that both layers are of other than merely transparent material, the exterior appearance presented by one leg is that of one layer while the exterior appearance presented by the other leg is that of the other layer. The two inserts would be different so as to present different appearances to respPctive sides of the edge guard.
Figs. 65 and 66 illustrate fur*her embodiments similar to Fig. 64.
An edge guard as in Fig. 67 may be fabricated from a plastic body which is of any suitable clear transparent plastic material. For retention purposes an adhesive means is 1 3 ~

applied to the interior surface of the inside leg and also preferably, but optionally, over an adjoining portion, one-half specifically, of the base as well. The outer leg is entirely free of any adhesive as is the immediately contiguous half of the base.
The adhesive means may comprise a double-backed adhesive tape of foam or fabric for example, containing adhesive on opposite faces.
Since it is the outside surface of the door which is exposed to view when the door is closed, it will therefore be the outer leg and the immediately contiguous portion of the base which will be visible. The typical automobile door is painted to a desired exterior color and therefore the clear transparent nature of the edge guard material, free of any attachment or adhesive means, will allow the underlying color of the door to show through along the trailing edge of the door. In other words, the effect of the edge guard is as if the edge guard itself were the exact same color as the painted door so that the edge guard itself will be imperceptible to a casual observer. Yet, the edge guard possesses the protective attribute of guarding against chipping of paint from the door edge such as when the door is swung open against an object in the path of travel of the door edge.
A desire for color coordination is not universally sought in door edge guards. Some door edge guards are preferred to present a metallic appearance such as chrome ~L ~s~ L d while others are desired to provide what is commonly referred to as a black-out function. These attributes can be advantageously embodied in a door edge guard according to Fig.
67. This is done by applying a layer 104 in covering relationship to exterior of the adhesive-contaning inside leg and the adjoining half of the curved base.
If it is desired to present the painted color of the door as the exterior appearance, then the edge ~uard is installed in the same manner with the outer leg 108 on the outside. However, if it is desired to present a black-out, or chrome, appearance, the edge guard's installation is reversed so that the inner leg becomes the outer leg and the outer leg becomes the inner leg, the layer being a black-out one for black-out appearance, or a metallic one for a chrome appearance. The fact that adhesive will now be present between the outer leg and the exterior surface of the door is of no consequence because it is concealed by layer 104.
While preferred embodiments of the invention have been disclosed, it will be appreciated that principles are applicable to other embodiments.

Claims

1. For the trailing edge of an object such as a swinging closure, the improvement in a decorative and protective edge guard for fitting onto such a trailing edge, comprising a non-metallic body having a curved base adapted for fitting over the end of the edge and legs extending from the base for fitting against opposite sides of the edge, said body containing notch structure formed in its surface and a layer of material cooperatively joined to said body and fitted to said notch structure, said layer overlying at least a portion of the exterior surface of said base and an adjoining portion of one of the legs.

2. The improvement of claim 1 in which said notch structure comprises an undercut formed in said body.

3. The improvement of claim 1 in which said notch structure comprises at least one slot formed in a leg of said body and a margin of said layer is inserted into said slot.

4. The improvement of claim 1 in which said base has a reduced thickness from that of said legs.

5. The improvement of claim 1 in which said notch structure comprises both an undercut and a slot in said body and a margin of said layer is disposed in said slot.

6. The improvement of claim 1 in which said layer comprises a transparent non-metallic material encapsulating a foil.

7. The improvement of claim 1 in which said notch structure begins at the center of said base, said layer extends from the beginning of said notch structure along said base and at least an adjoining portion of said one leg, and said layer presents a different exterior appearance from that presented by the other of the legs.

8. The improvement of claim 7 in which the exterior appearance presented by said other leg is that of said non-metallic body.

9. The improvement of claim 7 in which said layer comprises a transparent non-metallic material encapsulating a metallic foil.

10. The improvement of claim 7 in which said notch structure is defined by a protuberance at the center of said base, said layer extending from one side of said protuberance, and including another layer of material cooperatively joined to the exterior surface of said body, said another layer extending from the other side of said notch structure along said base and at least an adjoining portion of the other of the legs, and the cooperative effect of said another layer and other leg presenting a different exterior appearance from that presented by the first-mentioned layer and said one leg.

11. The improvement of claim 7 in which said body is of clear appearance and such clear appearance is different from the appearance presented by said layer.

12. The improvement of claim 1 in which side edges of said layer of material that extend lengthwise of the edge guard are embedded into the material of said body.

13. The improvement of claim 12 in which said body, viewed endwise, is essentially symmetrical about an imaginary plane that divides the base into two halves, and said layer, viewed endwise of the edge guard, covers essentially exactly one half of the exterior surface of said base and at least substantially all the exterior surface of the adjoining leg, the other half of the exterior surface of said base and the exterior surface of the other leg being uncovered.

14. The improvement of claim 1 in which said body has said legs of thickness greater than that of said base and the thickness of said base toward said inner leg is less than the thickness of said base toward said outer leg.

15. The improvement of claim 14 in which the thickness of said base is substantially uniform along an angular extent from the midpoint of said base to approximately 45 toward said inner leg, and beyond said angular extent, the thickness pogressively increases to merge into the thickness of said inner leg.

16. The improvement of claim 14 in which the interior surface of said base is curved and the exterior surface of said base is straight from the midpoint of said base to the beginning of said inner leg.

17. For use with the trailing edge of a front swinging closure which is separated from the leading edge of a rear swinging closure by a gap, and wherein said leading edge of said rear swinging closure, upon opening from closed position, executes a small component of motion toward the trailing edge of said front swinging closure, an improved decorative and protective edge guard for fitting onto the trailing edge of the front swinging closure, comprising a non-metallic body having in transverse cross section a curved base fitting over the end of said trailing edge and inner and outer legs extending from said base over the sides of said trailing edge, said body having said legs of thickness greater than that of said base and the thickness of said base toward said inner leg being less than the thickness of said base toward said outer leg.

18. In combination with a swinging closure having a trailing edge, the improvement in a decorative and protective edge guard fitted onto the trailing edge of the swinging closure, comprising a non-metallic body having a curved base fitting over the edge and legs extending from the base to fit against sides of the swinging closure adjacent the edge, said body, viewed endwise, is essentially symmetrical about an imaginary plane that divides the base into two halves, a layer of material cooperatively joined to said body and which, viewed endwise of the edge guard, covers essentially exactly one half of the exterior surface of said base and at least substantially all the exterior surface of the adjoining leg and in which side edges of said layer of material that extend lengthwise of the edge guard are embedded into the material of said body, and the other half of the exterior surface of said base and the exterior surface of the other leg are uncovered.