US6000814A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Vehicular component assembly with hard coated element
Assignee: Magna Donnelly Corp
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Filing: 1997-07-17
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Granted: 1999-12-14
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Expires: 2017-07-17
Abstract
Abstract A vehicle component assembly includes a hard coated polymeric element with a resinous polymeric molded element or gasket integrally molded to a predetermined area thereof. Preferably, the element is a polycarbonate optical lens, such as a headlight lens, which is coated with a protective coating or hard coat which provides abrasion resistance and optionally includes ultraviolet radiation absorbers to protect the resinous polymeric molded element from UV radiation degradation. Adhesion is improved by priming the area of the polycarbonate element which receives the gasket with a primer coating. Preferably, the area to be gasketed is primed with a first adhesion promoting primer followed by a second adhesion promoting primer, wherein the first adhesion promoting primer improves the adhesion of the second primer to the protective coating, while the second primer, in turn, improves the adhesion of the molded element or gasket to the first primer and the hard coated element. The gasket is preferably molded on a peripheral portion of the element which may include grooves or other formed portions for mechanical interlocking the gasket with the polymeric element. Preferably, the gasket is formed from a melt-processible gasket material, such as polyvinyl chloride, thermoplastic urethane, or an ethylene-styrene polymer.
Inventors
- 👤 David E. Nestell
- 👤 James T. Ainsworth
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 14:09
CPC Classifications
F; F21; F21S; F21S45/00; F21S45/10; B; B29; B29C; B29C45/00; B29C45/14; B29C45/14311; F21S41/00; F21S41/20; F21S41/28; F21S41/29; B29C45/14336; B29C2045/14459; B29L; B29L2011/00; B29L2011/0016; B29L2031/00; B29L2031/26; B29L2031/265; B29L2031/30; B29L2031/747; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31507
Claims Analysis
Total Claims: 74
Claim 1
Independent Claim
170 words
A vehicular lighting assembly optical component for a vehicle, the vehicle having a body and an opening in the body, said vehicular lighting assembly optical component comprising: a polymeric optical element having a peripheral portion, said peripheral portion having inner and outer peripheral side surfaces and a peripheral edge surface, said polymeric optical element including a protective coating and a primer coating, said protective coating being on at least one of said inner peripheral side surface, said outer peripheral side surface, and said peripheral edge surface, said primer coating being on a predetermined area of said protective coating; and a gasket material integrally molded on and bonded to at least a portion of said primed area on at least one of said inner peripheral side surface, said outer peripheral side surface, and said peripheral edge surface of said polymeric optical element, said gasket material having extending portions at positions spaced from said optical element adapted to cover a gap between said polymeric optical element and the opening in the body.
Claim 2
Dependent Claim
170 words
A vehicular lighting assembly optical component for a vehicle, the vehicle having a body and an opening in the body, said vehicular lighting assembly optical component comprising: a polymeric optical element having a peripheral portion, said peripheral portion having inner and outer peripheral side surfaces and a peripheral edge surface, said polymeric optical element including a protective coating and a primer coating, said protective coating being on at least one of said inner peripheral side surface, said outer peripheral side surface, and said peripheral edge surface, said primer coating being on a predetermined area of said protective coating; and a gasket material integrally molded on and bonded to at least a portion of said primed area on at least one of said inner peripheral side surface, said outer peripheral side surface, and said peripheral edge surface of said polymeric optical element, said gasket material having extending portions at positions spaced from said optical element adapted to cover a gap between said polymeric optical element and the opening in the body.
Claim 3
Dependent Claim
20 words
A vehicular lighting assembly optical component according to claim 1, wherein said polymeric optical element comprises a polycarbonate optical element.
Claim 4
Dependent Claim
17 words
A vehicular lighting assembly optical component according to claim 2, wherein said optical element comprises a lens.
Claim 5
Dependent Claim
42 words
A vehicular lighting assembly optical component according to claim 3, wherein said gasket material is injection molded on at least a portion of said primed area on at least said inner peripheral side surface and said peripheral edge surface of said lens.
Claim 6
Dependent Claim
27 words
A vehicular lighting assembly optical component according to claim 4, wherein said lens includes at least one cooperating structure mechanically interlocking said gasket material with said lens.
Claim 7
Dependent Claim
32 words
A vehicular lighting assembly optical component according to claim 5, wherein said cooperating structure comprises a groove, said groove extending around at least a portion of said peripheral portion of said lens.
Claim 8
Dependent Claim
30 words
A vehicular lighting assembly optical component according to claim 5, wherein said cooperating structure comprises one of a lip and a spaced through-hole mechanically bonding said gasket and said lens.
Claim 9
Dependent Claim
55 words
A vehicular lighting assembly optical component according to claim 1, wherein said primer coating comprises a first primer coating, said optical element including a second primer coating between said first primer coating and said gasket material, said first primer coating increasing the adhesion of said second primer coating and gasket material to said protective coating.
Claim 10
Dependent Claim
27 words
A vehicular lighting assembly optical component according to claim 1, wherein said gasket material comprises one of a melt-processible gasket material and a non melt-processible gasket material.
Claim 11
Dependent Claim
58 words
A vehicular lighting assembly optical component according to claim 9, wherein said gasket material comprises a melt-processible gasket material selected from the group including polyvinyl chloride, a styrene/butadiene/styrene elastomer, a styrene/ethylene/butadiene/styrene elastomer, a copolyester elastomer, a polyether blockamide, a thermoplastic urethane, a styrene butadiene rubber elastomer, an ethylene propylene diene terpolymer elastomer, and an ethylene propylene copolymer elastomer.
Claim 12
Dependent Claim
17 words
A vehicular lighting assembly optical component according to claim 9, wherein said gasket material comprises a urethane.
Claim 13
Dependent Claim
18 words
A vehicular lighting assembly optical component according to claim 1, wherein said polymeric optical element comprises a lens.
Claim 14
Dependent Claim
34 words
A vehicular lighting assembly optical component according to claim 12, wherein said lens comprises a head lamp lens and includes a contoured surface adapted to follow the contour of the body of the vehicle.
Claim 15
Dependent Claim
17 words
A vehicular lighting assembly optical component according to claim 13, wherein said lens comprises a polycarbonate lens.
Claim 16
Dependent Claim
16 words
A vehicular lighting assembly optical component according to claim 1, wherein said protective coating is transparent.
Claim 17
Dependent Claim
27 words
A vehicular lighting assembly optical component according to claim 1, wherein said protective coating comprises one of an organic coating, an inorganic coating, and an organic/inorganic coating.
Claim 18
Dependent Claim
19 words
A vehicular lighting assembly optical component assembly according to claim 16, wherein said protective coating comprises a silicone coating.
Claim 19
Dependent Claim
25 words
A vehicular lighting assembly optical component assembly according to claim 16, wherein said protective coating comprises one of a silicon dioxide and a titanium dioxide.
Claim 20
Dependent Claim
21 words
A vehicular lighting assembly optical component assembly according to claim 16, wherein said protective coating comprises a silicone modified metal oxide.
Claim 21
Dependent Claim
20 words
A vehicular lighting assembly optical component assembly according to claim 1, wherein said optical component includes an ultraviolet radiation absorber/stabilizer.
Claim 22
Dependent Claim
28 words
A vehicular lighting assembly optical component assembly according to claim 20, wherein said ultraviolet radiation absorber/stabilizer being incorporated into one of said optical element and said protective coating.
Claim 23
Dependent Claim
22 words
A vehicular lighting assembly optical component assembly according to claim 20, wherein said ultraviolet radiation absorber/stabilizer is incorporated into said protective coating.
Claim 24
Dependent Claim
40 words
A vehicular lighting assembly optical component assembly according to claim 20, wherein said optical element further includes an intermediate primer coating between said optical element and said protective coating, said ultraviolet radiation absorber/stabilizer being incorporated into said intermediate primer coating.
Claim 25
Dependent Claim
18 words
A vehicular lighting assembly optical component according to claim 1, wherein said peripheral edge surface is substantially smooth.
Claim 26
Dependent Claim
31 words
A vehicular lighting assembly optical component according to claim 1, wherein said peripheral portion includes a cooperating structure, said cooperating structure mechanically bonding said gasket material to said polymeric optical element.
Claim 27
Dependent Claim
113 words
A vehicle lighting assembly, said vehicle lighting assembly comprising: a housing; and a lens module mounted to said housing, said housing being adapted for mounting in an opening of a vehicle, said lens module including a lens having an exterior surface, a peripheral edge and a peripheral portion adjacent said peripheral edge, said lens module including a protective coating on at least said exterior surface for protecting said lens from abrasion, a primer coating over at least a portion of said protective coating, and a gasket integrally molded on at least a portion of the primed portion, and said gasket being adapted to cover a gap between the vehicle opening and said lens.
Claim 28
Dependent Claim
113 words
A vehicle lighting assembly, said vehicle lighting assembly comprising: a housing; and a lens module mounted to said housing, said housing being adapted for mounting in an opening of a vehicle, said lens module including a lens having an exterior surface, a peripheral edge and a peripheral portion adjacent said peripheral edge, said lens module including a protective coating on at least said exterior surface for protecting said lens from abrasion, a primer coating over at least a portion of said protective coating, and a gasket integrally molded on at least a portion of the primed portion, and said gasket being adapted to cover a gap between the vehicle opening and said lens.
Claim 29
Dependent Claim
15 words
A vehicle lighting assembly according to claim 26 wherein said lens comprises a polycarbonate lens.
Claim 30
Dependent Claim
24 words
A vehicle lighting assembly according to claim 26, wherein said gasket comprises one of a melt-processible gasket material and a non melt-processible gasket material.
Claim 31
Dependent Claim
55 words
A vehicle lighting assembly according to claim 28, wherein said gasket comprises a melt-processible gasket material selected from the group including polyvinyl chloride, a styrene/butadiene/styrene elastomer, a styrene/ethylene/butadiene/styrene elastomer, a copolyester elastomer, a polyether blockamide, a thermoplastic urethane, a styrene butadiene rubber elastomer, an ethylene propylene diene terpolymer elastomer, and an ethylene propylene copolymer elastomer.
Claim 32
Dependent Claim
14 words
A vehicle lighting assembly according to claim 28, wherein said gasket comprises a urethane.
Claim 33
Dependent Claim
45 words
A vehicle lighting assembly according to claim 26, wherein said primer coating comprises a first primer coating, said lens module including a second primer coating, said first primer coating improving the adhesion of said second primer coating and said gasket material to said protective coating.
Claim 34
Dependent Claim
90 words
A vehicle lighting assembly according to claim 26, wherein said peripheral portion of said lens has an inner peripheral side surface, an outer peripheral side surface, and a peripheral edge surface, said gasket being molded onto at least one of said inner peripheral side surface, said outer peripheral side surface, and said peripheral edge surface, said at least one of said inner peripheral side surface, said outer peripheral side surface, and said peripheral edge surface including said primer coating to improve the adhesion between said gasket and said protective coating.
Claim 35
Dependent Claim
44 words
A vehicle lighting assembly according to claim 32, wherein said inner peripheral side surface of said lens includes a cooperating structure, said gasket being injected into said cooperating structure to provide mechanical interlocking of said gasket with said lens to form said lens module.
Claim 36
Dependent Claim
47 words
A vehicle lighting assembly according to claim 26, wherein said gasket includes a flange, said flange extending from said peripheral portion of said lens thereby defining a lip, and at least a portion of said lip being adapted to extend under a body panel of the vehicle.
Claim 37
Dependent Claim
28 words
A vehicle lighting assembly according to claim 34, wherein said lip of said gasket has a lateral dimension, said lateral dimension varying along a length of said gasket.
Claim 38
Dependent Claim
15 words
A vehicle lighting assembly according to claim 35, wherein said lip has a varying thickness.
Claim 39
Dependent Claim
42 words
A vehicle lighting assembly according to claim 34, wherein at least a portion of said lip of said gasket has a free end adapted for engaging at least a portion of the perimeter of an opening in the body of the vehicle.
Claim 40
Dependent Claim
19 words
A vehicle lighting assembly according to claim 26, wherein said lens module comprises an exterior lighting assembly lens module.
Claim 41
Dependent Claim
21 words
A vehicle lighting assembly according to claim 38, wherein said exterior lighting assembly lens module comprises a headlamp assembly lens module.
Claim 42
Dependent Claim
15 words
A vehicle lighting assembly according to claim 39, wherein said lens comprises a polycarbonate lens.
Claim 43
Dependent Claim
32 words
A vehicle lighting assembly according to claim 26, wherein said lens includes a contoured outer surface, said contoured outer surface being adapted to follow the contour of the body of the vehicle.
Claim 44
Dependent Claim
32 words
A vehicle lighting assembly according to claim 26, wherein said lens module includes a projecting flange, said projecting flange being secured to said housing to secure said lens module to said housing.
Claim 45
Dependent Claim
27 words
A vehicle lighting assembly according to claim 26, wherein said protective coating comprises at least one of an organic coating, an inorganic coating, and an organic/inorganic coating.
Claim 46
Dependent Claim
25 words
A vehicle lighting assembly according to claim 26, wherein said lens module includes an ultraviolet radiation absorber/stabilizer for protecting said lens from ultraviolet radiation damage.
Claim 47
Dependent Claim
31 words
A vehicle lighting assembly according to claim 44, wherein said ultraviolet absorber/stabilizer is incorporated into one of said lens and said protective coating for protecting said lens from ultraviolet radiation degradation.
Claim 48
Dependent Claim
43 words
A vehicle lighting assembly according to claim 44, said lens module further including an intermediate primer coating between said lens and said protective coating, said ultraviolet radiation absorber/stabilizer being incorporated into said intermediate primer coating for protecting said lens from ultraviolet radiation degradation.
Claim 49
Dependent Claim
50 words
A vehicular component assembly for positioning in a vehicle, said vehicular component assembly comprising: a polymeric body having a protective coating, and at least one primer coating overlaying at least a portion of said protective coating; and a member integrally molded onto at least a portion of said primer coating.
Claim 50
Dependent Claim
50 words
A vehicular component assembly for positioning in a vehicle, said vehicular component assembly comprising: a polymeric body having a protective coating, and at least one primer coating overlaying at least a portion of said protective coating; and a member integrally molded onto at least a portion of said primer coating.
Claim 51
Dependent Claim
23 words
A vehicular component assembly according to claim 47, further comprising an ultraviolet radiation absorber/stabilizer for protecting said polymeric body from ultraviolet radiation degradation.
Claim 52
Dependent Claim
38 words
A vehicular component assembly according to claim 47, wherein said polymeric body including at least one cooperating structure, said member being molded and extending into said cooperating structure to thereby mechanically interlock said member with said polymeric body.
Claim 53
Dependent Claim
84 words
A vehicular component assembly according to claim 47, wherein said polymeric body includes a peripheral portion, said peripheral portion having inner and outer peripheral side surfaces and a peripheral edge surface, said member being molded onto at least a portion of said primer coating on at least one of said inner and outer peripheral side surfaces and said peripheral edge surface to form a gasket, and said gasket being adapted to cover a gap between said polymeric body and an opening in the vehicle.
Claim 54
Dependent Claim
24 words
A vehicle component assembly according to claim 50, wherein said member is injection molded on said inner peripheral side surface of said polymeric body.
Claim 55
Dependent Claim
34 words
A vehicle component assembly according to claim 51, wherein at least a portion of said inner peripheral side surface includes a projecting lip, said projecting lip mechanically interlocking said member with said polymeric body.
Claim 56
Dependent Claim
25 words
A vehicle component assembly according to claim 47, wherein said protective coating comprises one of an organic coating, an inorganic coating, and an organic/inorganic coating.
Claim 57
Dependent Claim
63 words
A vehicle component assembly according to claim 47, wherein said at least one primer coating comprises a first primer coating, said body including a second primer coating over said first primer coating, said first primer coating improving the adhesion between said second primer coating and said protective coating, said second primer coating improving the adhesion between said member and said first primer coating.
Claim 58
Dependent Claim
24 words
A vehicle component assembly according to claim 47, wherein said member comprises one of a melt-processible gasket material and a non melt-processible gasket material.
Claim 59
Dependent Claim
55 words
A vehicle component assembly according to claim 55, wherein said member comprises a melt-processible gasket material selected from the group including polyvinyl chloride, a styrene/butadiene/styrene elastomer, a styrene/ethylene/butadiene/styrene elastomer, a copolyester elastomer, a polyether blockamide, a thermoplastic urethane, a styrene butadiene rubber elastomer, an ethylene propylene diene terpolymer elastomer, and an ethylene propylene copolymer elastomer.
Claim 60
Dependent Claim
14 words
A vehicle component assembly according to claim 55, wherein said member comprises a urethane.
Claim 61
Dependent Claim
19 words
A vehicle component assembly according to claim 47, wherein said polymeric body comprises a lens for a lighting assembly.
Claim 62
Dependent Claim
23 words
A vehicle component assembly according to claim 58, further comprising an ultraviolet radiation absorber/stabilizer for protecting said polymeric body from ultraviolet radiation degradation.
Claim 63
Independent Claim
77 words
A method of attaching a molded member to a polymeric vehicle element, the method comprising the steps of: providing a polymeric vehicle element, the polymeric vehicle element having a protective coating; applying a primer to a predetermined area of the protective coating; and forming an integrally molded member on at least a portion of the predetermined primed area from a gasket material, the primer bonding the molded member to the protective coating and the polymeric vehicle element.
Claim 64
Independent Claim
77 words
A method of attaching a molded member to a polymeric vehicle element, the method comprising the steps of: providing a polymeric vehicle element, the polymeric vehicle element having a protective coating; applying a primer to a predetermined area of the protective coating; and forming an integrally molded member on at least a portion of the predetermined primed area from a gasket material, the primer bonding the molded member to the protective coating and the polymeric vehicle element.
Claim 65
Dependent Claim
21 words
A method according to claim 60, wherein forming a member comprises injection molding the gasket molding material onto the polymeric element.
Claim 66
Dependent Claim
20 words
A method according to claim 61, wherein injection molding comprises reaction injection molding the molded member onto the polymeric element.
Claim 67
Dependent Claim
32 words
A method according to claim 60, wherein applying a primer includes applying at least one glass primer selected from the group consisting of an acrylic-based glass primer and a urethane-based glass primer.
Claim 68
Dependent Claim
15 words
A method according to claim 60, further including allowing the glass primer to flash completely.
Claim 69
Dependent Claim
65 words
A method according to claim 60, wherein applying a primer to the polymeric vehicle element comprises: applying a first primer to the predetermined area; and applying a second primer to the predetermined area after the first primer, the first primer improving the adhesion between the protective coating and the second primer, the second primer improving the adhesion between the first primer and the molded member.
Claim 70
Dependent Claim
25 words
A method according to claim 60, wherein applying a primer to the vehicle element comprises applying a primer to a peripheral portion of the element.
Claim 71
Dependent Claim
33 words
A method according to claim 61, wherein injection molding a gasket molding material includes injection molding one of a melt-processible gasket material and a non melt-processible gasket material onto the polymeric vehicle element.
Claim 72
Dependent Claim
21 words
A method according to claim 60, further comprising preheating the vehicle polymeric element prior to applying the primer to the element.
Claim 73
Dependent Claim
20 words
A method according to claim 68, wherein preheating the vehicle polymeric element comprises applying warm air to the polymeric element.
Claim 74
Dependent Claim
28 words
A method according to claim 60, wherein said providing a polymeric vehicle element includes providing a protective coated polymeric vehicle element having an ultraviolet radiation absorber/stabilizer incorporated therein.
References Cited (Backward Citations)
US5560706A
Cited
US5552970A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2002-12-13 | 2003-06-14 | 2003-12-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-12-13 | 2007-06-14 | 2007-12-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-12-13 | 2011-06-14 | 2011-12-14 | $7700.00 | Window Closed / Lapsed |