Note: Descriptions are shown in the official language in which they were submitted.
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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
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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
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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
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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
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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
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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,
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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
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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
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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
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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
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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
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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
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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.
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