WO2019182595A1

WO2019182595A1 - Door checker dust cover

Info

Publication number: WO2019182595A1
Application number: PCT/US2018/023714
Authority: WO
Inventors: David Andrew PEARCE; Paul John Norton PERKINS
Original assignee: Multimatic Patentco Llc
Priority date: 2018-03-22
Filing date: 2018-03-22
Publication date: 2019-09-26

Abstract

A door checker dust cover includes first and second side portions that extend from a base portion. At least one of the first and second side portions are joined to the base portion by a living hinge. The base portion has an opening configured to receive a door checker check strap. The first and second side portions are configured to fold relative to one another about the living hinge from an open position to a sealed position and secure to one another around a door checker.

Description

DOOR CHECKER DUST COYER

BACKGROUND

[0001] This disclosure relates to a dust cover for a motor vehicle door checker.

[0002] A door checker is commonly used in an automotive vehicle to hold a door in one of several discrete open positions. Typically, the door checker housing is mounted within a door cavity, and a check arm extends through the housing and attaches at one end to a vehicle pillar. The check arm includes a profile with a groove that has a variable height and several spaced apart pockets that correspond to the discrete open positions. A pair of spring loaded balls is arranged within the housing and cooperates with opposing sides of the check arm to provide a desired lateral and longitudinal holding force on the check arm.

[0003] The check arm extends into the door cavity. In one typical arrangement, the housing secured to the door and a portion of the check arm is at least partially exposed to the door cavity. Some water and debris is able to enter the door cavity past the wiper that seals the window relative to the door. To this end, it is desirable to cover the exposed portion of the door checker within the door cavity with a dust cover to protect the exposed door checker components from the elements.

[0004] One example dust cover is disclosed in United States Patent No. 6,145,163 to Mitchell. This cover is constructed from a rubber material that is rather expensive and is more heavy than desired. Another dust cover, disclosed in United States Patent No. 9,316,032 to Roy, is stamped from metal and suffers the same drawbacks as Mitchell. A two-piece foam cover is disclosed in United States Patent No. 8,616,558 to Fischer, but this dust cover may be torn during assembly.

[0005] What is needed is a door checker dust cover that is inexpensive, simple to reliably assemble and light.

SUMMARY

[0006] In one exemplary embodiment, a door checker dust cover includes first and second side portions that extend from a base portion. At least one of the first and second side portions are joined to the base portion by a living hinge. The base portion has an opening configured to receive a door checker check strap. The first and second side portions are configured to fold relative to one another about the living hinge from an open position to a sealed position and secure to one another around a door checker.

[0007] In a further embodiment of any of the above, the first and second portions are joined to the base portion respectively by first and second living hinges.

[0008] In a further embodiment of any of the above, the opening is generally diamond-shaped and is configured to receive the door checker strap and fasteners extending therethrough.

[0009] In a further embodiment of any of the above, the first and second sides respectively include first and second perimeter portions that surround a cavity therebetween that is configured to receive the door checker. The first and second perimeter portions seal with one another in the sealed position.

[0010] In a further embodiment of any of the above, the first and second perimeter portions respectively include a recess and a protrusion that at least partially circumscribe the cavity arranged in a nesting relationship in the sealed position.

[0011] In a further embodiment of any of the above, the first and second portions include interlocking features that cooperate with one another to maintain the first and second portions in the sealed position.

[0012] In a further embodiment of any of the above, the door checker dust cover is a thermoformed plastic.

[0013] In a further embodiment of any of the above, the base portion includes laterally spaced apart triangular portions that extend from a side of the base portion. The first and second sides each include a lip that engages a ledge of the triangular portions in the sealed position.

[0014] In a further embodiment of any of the above, at least one of the first and second portions includes a pocket that provides a cavity that is configured to receive the door checker. At least one of the first and second portions has a lateral wall that provides a shoulder that at least partially defines the pocket. The shoulder is configured to abut the door checker in the sealed position.

[0015] In another exemplary embodiment, a door checker assembly includes a door checker that includes a housing that movably supports a check strap. The housing has a face with a window through which the check strap extends. A dust cover has first and second side portions that extend from a base portion. The base portion abuts the face and includes an opening through which the check strap extends. The first and second side portions are secured to one another in a sealed position around the housing.

[0016] In a further embodiment of any of the above, the door checker includes fasteners that extend from the face and through the base portion.

[0017] In a further embodiment of any of the above, the first and second portions are joined to the base portion respectively by first and second living hinges.

[0018] In a further embodiment of any of the above, the first and second sides respectively include first and second perimeter portions that surround a cavity therebetween that is configured to receive the door checker. The first and second perimeter portions are sealed with one another in the sealed position.

[0019] In a further embodiment of any of the above, the first and second perimeter portions respectively include a recess and a protrusion at least partially circumscribing the cavity arranged in a nesting relationship in the sealed position.

[0020] In a further embodiment of any of the above, the first and second portions include interlocking features that cooperate with one another to maintain the first and second portions in the sealed position.

[0021] In a further embodiment of any of the above, the at least one of the first and second portions includes a pocket that provides a cavity that is configured to receive the door checker. At least one of the first and second portions has a lateral wall that provides a shoulder that at least partially defines the pocket. The shoulder is configured to abut the door checker in the sealed position.

[0022] In another exemplary embodiment, a method of manufacturing a door checker assembly that has a door checker with a housing that includes a face that has a window. A check strap extends through the window. The method includes inserting the check strap through an opening in a dust cover base portion to abut the face against the base portion. The dust cover is folded about the housing to seal the dust cover about the door checker.

[0023] In a further embodiment of any of the above, the folding step includes folding opposing side portions relative to and in sealing engagement with one another.

[0024] In a further embodiment of any of the above, the first and second sides respectively include first and second perimeter portions that surround a cavity therebetween that is configured to receive the door checker. The first and second perimeter portions respectively include a recess and a protrusion that at least partially circumscribe the cavity arranged in a nesting relationship in a sealed position.

[0025] In a further embodiment of any of the above, at least one of the first and second portions includes a pocket that provides a cavity that is configured to receive the door checker. At least one of the first and second portions has a lateral wall that provides a shoulder at least partially defining the pocket. The shoulder is configured to abut the door checker in a sealed position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0027] Figure 1 is a schematic view of a portion of a vehicle having a door with a door checker.

[0028] Figure 2 is a perspective view of a door checker embodiment.

[0029] Figure 3 is a perspective view of one disclosed dust cover embodiment sealed about the door checker.

[0030] Figure 4 is a partial cross-sectional schematic plan view of a portion of the dust cover captured between the door checker and the door.

[0031] Figure 5 is a perspective view of the dust cover in an open position.

[0032] Figures 6A-6C are respectively perspective, elevational and side views of the dust cover in the open position with a housing of the door checker arranged within the dust cover.

[0033] Figure 7A is a cross-sectional view through portions of base and side portions with the dust cover in a sealed position.

[0034] Figure 7B is a cross-sectional view through portions of first and second side portions with the dust cover in the sealed position.

[0035] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

DETAILED DESCRIPTION

[0036] A portion of a vehicle 10 is schematically shown in Figure 1. The vehicle 10 includes a door 12 arranged within a door opening 14. The door 12 may or may not incorporate an exterior door handle. The door 12 is supported with respect to an A-pillar 16 by hinges 20. An end of the door 12 opposite the hinges 20 is secured to a B-pillar 18 by a latching assembly 26. A- and B-pillars are typically referred to as body pillars. The latching assembly 26 typically includes a latch 28 carried by a door that cooperates with a striker 30 secured to the B-pillar 18. A separate door checker 22 is arranged at the hinge end of the door 12 and holds the door 12 in multiple open positions sufficiently spaced from the vehicle 10 to permit egress and ingress of the occupant through the door opening 14.

[0037] An example door checker 22 is shown in more detail in Figure 2. A check strap 42 is received in a housing 52. A stop 44 is provided at one end of the check strap 42 to limit the travel of the door 12 in the fully open position. The other end of the check strap 42 includes a clevis 46 that is typically secured to the A-pillar 16.

[0038] A separate door checker 22, for example, as described in United States Patent No. 5,173,991 to Carswell, is conventionally used at each vehicle door to hold the door in one or more discrete open positions. The check strap 42 includes a groove 48 providing a profile. The groove 48 includes multiple depressions or pockets 50a-50c that correspond to these discrete door open positions known in the art as detent positions. The check strap 42 extends through a window 54 in the housing 52. A ball 56 is biased into engagement with the groove 48 by a spring 58. Typically another ball and spring are arranged on the other side of the check strap 42, which has a corresponding groove. These spring loaded balls provide sufficient holding force when seated in a pocket.

[0039] Referring to Figure 2, the pockets 50a-50c correspond to typical door open positions in which an occupant can enter or exit the vehicle through the door opening. Other door checker configurations including hinge integrated door checkers (i.e., co-located with or part of one of the hinges) can be used to perform this function providing that a detent is added at the door ajar position. One such example door hinge with integrated door checker is United States Patent No. 6,481,056 to Jesse.

[0040] The housing 52 includes a flange 60 that provides a face 62 for securing the door checker 22 to the door 12. In the example arrangement, the flange supports a pair of fasteners 66, such as studs, although the flange 60 may provide threaded holes for receiving bolts that secure the door checker to the door. Referring to Figures 3 and 4, a dust cover 70 is secured about the door checker 22 in a sealed position to protect the door checker 22 from the elements. The dust cover 70 is a one-piece unitary structure that may be vacuum-formed from a polymer material such as acrylonitrile butadiene styrene (ABS), polypropylene (PP), high density polyethylene (HDPE), or any other suitable material.

[0041] The dust cover 70 includes a base portion 72 having an opening 78 through which the check strap 42 and the fasteners 66 extend. The base portion 72 is captured between the housing 52 and the door 12 when the door checker assembly is installed into the door. The opening 78 is generally diamond- shaped and includes first and second edges 80, 82 that are in close proximity to the fasteners 66 to generally locate the door checker 22 with respect to the dust cover 70 when installed into the dust cover 70 in the open position (Figs. 6A-6C). An enlarged region 84 is provided generally centrally between the first and second edges 80, 82 to accommodate the movement of the check strap 42 during operation. In the example, other than the opening 78 in the base portion 72, there are no other holes in the dust cover 70.

[0042] Referring to Figures 5-6C, first and second side portions 74, 76 extend from the base portion 72. At least one of the first and second side portions 74, 76 are joined to the base portion 72 by a living hinge to enable the dust cover 70 to be folded and closed about the door checker 22. In the example, each of the first and second side portions 74, 76 are joined to the base portion 72 respectively by first and second living hinges 75, 77 and fold relative to one another about the living hinges (see folding directional arrows in Fig. 6C) from an open position to a sealed position secured to one another around the door checker 22.

[0043] The first and second side portions 74, 76 respectively include first and second perimeter portions 174, 176 defining first and second pockets 71, 73 that form a cavity 79 (Fig. 3) there between which receives the door checker 22. The first and second perimeter portions 174, 176 seal with one another in the sealed position using a recess 98 and protrusion 100 arranged about their respective perimeters to at least partially circumscribe the cavity 79. The recess 98 and protrusion 100 nest with one another in the sealed position, as best shown in Figure 7A.

[0044] Referring to Figures 5 and 7B, the base portion 72 includes a triangular portion 86 on each lateral side. The triangular portion 86 includes a wall 87 that provides a ledge 88. Ends of each of the first and second side portions 74, 76 provide an S-shaped lip 90 that cooperates with the triangular portion 86 to seal the ends of the first and second side portions 74, 76 with the base portion 72. The S-shaped lip 90 is provided by sidewall 92, and first and second legs 94, 96 that cooperate with the triangular portion 86 to create a tortuous path for debris.

[0045] While the recess 98 and protrusion 100 may be sufficient to maintain the first and second side portions 74, 76 in the sealed position, it may be desirable to provide additional interlocking features 108 (Fig. 7A) to further maintain the dust cover 70 in the sealed position. To this end, the interlocking features 108 may include tabs 104 and indentations 106 respectively provided on the first and second side portions 74, 76 that are coupled to one another in the sealed position, as shown in Figure 7A.

[0046] As shown in Figures 5-6C, the first and second side portions 74, 76 include a shoulder 110 provided by the sidewall 92 that abuts the housing 52 with the dust cover 70 in a sealed position (Fig. 3) to maintain the face 62 against the base portion 72.

[0047] The disclosed door checker assembly is manufactured by inserting the check strap 42 through the opening 78 in the base portion 72 such that the face 62 abuts the base portion 72. The dust cover 70 is folded about the housing 52 to seal the dust cover 70 about the door checker 22. In the disclosed arrangement, the first and second side portions 74, 76 are folded about the first and second living hinges 75, 77 and into engagement with one another. The recess 98 and a protrusion 100 respectively provided on the first and second perimeter portions 174, 176 of the first and second side portions 74, 76 are arranged in a nested relationship in the sealed positon to form the cavity 79 that protects the door checker 22 from debris. The shoulders 110 provided by the sidewalls 92 maintain the door checker 22 against the base portion 72 during handling while the dust cover assembly is inserted and secured to the door 12 so that bumping the fasteners 66 does not push the door checker 22 into the cavity 79. [0048] The one-piece, light-weight thermoformed plastic dust cover 70 provides protection for the door checker 22 during vehicle use, while maintaining its integrity during vehicle assembly. The simplicity of design and the locating and locking features provided on the dust cover 70 enables the door checker assembly to be assembled quickly and accurately.

[0049] It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.

[0050] Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

[0051] Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.

Claims

CLAIMS What is claimed is:

1. A door checker dust cover comprising:

first and second side portions extending from a base portion, at least one of the first and second side portions joined to the base portion by a living hinge, the base portion having an opening configured to receive a door checker check strap, the first and second side portions configured to fold relative to one another about the living hinge from an open position to a sealed position and secure to one another around a door checker.

2. The door checker dust cover of claim 1, wherein the first and second portions are joined to the base portion respectively by first and second living hinges.

3. The door checker dust cover of claim 1, wherein the opening is generally diamond-shaped and configured to receive the door checker strap and fasteners extending therethrough.

4. The door checker dust cover of claim 1, wherein the first and second sides respectively include first and second perimeter portions surrounding a cavity therebetween that is configured to receive the door checker, the first and second perimeter portions sealing with one another in the sealed position.

5. The door checker dust cover of claim 4, wherein the first and second perimeter portions respectively include a recess and a protrusion at least partially circumscribing the cavity arranged in a nesting relationship in the sealed position.

6. The door checker dust cover of claim 1, wherein the first and second portions include interlocking features that cooperate with one another to maintain the first and second portions in the sealed position.

7. The door checker dust cover of claim 1, wherein the door checker dust cover is a thermoformed plastic.

8. The door checker dust cover of claim 1, wherein the base portion includes laterally spaced apart triangular portions extending from a side of the base portion, the first and second sides each include a lip engaging a ledge of the triangular portions in the sealed position.

9. The door checker dust cover of claim 1, wherein the at least one of the first and second portions includes a pocket providing a cavity configured to receive the door checker, the at least one of the first and second portions has a lateral wall providing a shoulder at least partially defining the pocket, the shoulder configured to abut the door checker in the sealed position.

10. A door checker assembly comprising:

a door checker including a housing movably supporting a check strap, wherein the housing has a face with a window through which the check strap extends;

a dust cover having first and second side portions extending from a base portion, wherein the base portion abuts the face and includes an opening through which the check strap extends, and the first and second side portions are secured to one another in a sealed position around the housing.

11. The door checker assembly of claim 10, wherein the door checker includes fasteners extending from the face and through the base portion.

12. The door checker assembly of claim 10, wherein the first and second portions are joined to the base portion respectively by first and second living hinges.

13. The door checker assembly of claim 10, wherein the first and second sides respectively include first and second perimeter portions surrounding a cavity therebetween that is configured to receive the door checker, the first and second perimeter portions sealing with one another in the sealed position.

14. The door checker assembly of claim 13, wherein the first and second perimeter portions respectively include a recess and a protrusion at least partially circumscribing the cavity arranged in a nesting relationship in the sealed position.

15. The door checker assembly of claim 10, wherein the first and second portions include interlocking features that cooperate with one another to maintain the first and second portions in the sealed position.

16. The door checker assembly of claim 10, wherein the at least one of the first and second portions includes a pocket providing a cavity configured to receive the door checker, the at least one of the first and second portions has a lateral wall providing a shoulder at least partially defining the pocket, the shoulder configured to abut the door checker in the sealed position.

17. A method of manufacturing a door checker assembly, the door checker assembly having a door checker with a housing including a face having a window, and a check strap extending through the window, the method comprising:

inserting the check strap through an opening in a dust cover base portion to abut the face against the base portion; and

folding the dust cover about the housing to seal the dust cover about the door checker.

18. The method of claim 17, wherein the folding step includes folding opposing side portions relative to and in sealing engagement with one another.

19. The method of claim 18, wherein the first and second sides respectively include first and second perimeter portions surrounding a cavity therebetween that is configured to receive the door checker, the first and second perimeter portions respectively include a recess and a protrusion at least partially circumscribing the cavity arranged in a nesting relationship in a sealed position.

20. The method of claim 18, wherein the at least one of the first and second portions includes a pocket providing a cavity configured to receive the door checker, the at least one of the first and second portions has a lateral wall providing a shoulder at least partially defining the pocket, and the shoulder is configured to abut the door checker in a sealed position.