Method of making a windshield and leaf screen assembly

#The present invention relates generally to a window assembly and to a process for producing the assembly, and more particularly to a windshield assembly for a vehicle including a glass viewing area having a gasket formed along at least one edge thereof including an integral leaf screen.

#Initially, fixed window assemblies for vehicles were comprised of a plurality of elements including adhesive sealants applied around the marginal edges of the window, suitable mechanical fasteners such as metal clips, and exterior decorative trim strips disposed to cover the junction between the marginal edges of the window and the adjacent portions of the vehicle frame. Such window structures were costly, especially from a labor standpoint, since it was necessary to assemble the individual elements along the vehicle assembly line.

#Subsequently, in an endeavor to improve the above window structure, unitary window assemblies of the type illustrated in U.S. Pat. No. 4,072,340 were developed. These assemblies included a sheet of glass, an adjacent frame, and a casing or gasket of molded material, such as polyvinylchloride, extending between the frame and the peripheral edge of the window to hold the sheet of glass and the frame together. Fasteners were provided at spaced locations along the frame such that the entire assembly could be guided into location over the opening in a vehicle body as a unit. Other types of unitary window assemblies are disclosed in U.S. Pat. Nos. 3,759,004 and 4,364,595. While such unitary window structures greatly reduce the time required to mount the window assembly in the associated vehicle, such structures are relatively costly, since the individual components required to produce each window assembly generally must be manually assembled.

#The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings, in which:

#FIG. 1 is a perspective view of a window assembly according to the present invention;

#FIG. 2 is an enlarged fragmentary sectional view of the window assembly of FIG. 1 taken along the line 2--2 thereof;

#There is shown in FIG. 1 a window assembly 10, according to the present invention, including a windshield 11, illustrated herein as including a pair of glass sheets and an interposed layer of polyvinylbvutyra integrally bonded to the sheets, having its peripheral edges encapsulated by a gasket 12. The gasket 12 includes a top portion 13, side portions 14 and 15, and bottom portion 16 which portions completely encapsulate the peripheral edges of the windshield 11. Attached to the bottom portion 16 is an integral leaf screen 17 and a locating tab means 18 extends from a front edge of the leaf screen 17. The leaf screen 17 replaces the prior art leaf screens which were typically formed of wire mesh, stamped steel or molded rigid plastic. These screens are utilized to prevent debris from falling into the engine compartment between the hood and body of those vehicles having windshield wipers mounted in that area. In order to provide for the passage of air between the exterior of the vehicle and the engine compartment, a plurality of elongated slots or apertures 19 are typically formed in the leaf screen 17.

#Referring to FIGS. 1 and 2, the gasket portions 13, 14, 15 and 16 completely encapsulate the peripheral edge of the windshield 11 to provide a seal against the intrusion of fluids between the windshield and the frame of the vehicle in which it is installed. Thus, the window assembly 10 is typically fitted into an opening in the vehicle and the gasket 12 is secured to the vehicle with a suitable adhesive. The leaf screen 17 is formed integral with the remaining portions of the gasket 12 and at the proper angle such that it fills an opening between the body of the vehicle and the hood of the vehicle. The tab means 18 can include one or more apertures 20 for receiving fastening means to secure the leading edge of the leaf screen, typically to the body of the vehicle.

#Referring to FIGS. 3 and 4, there is shown a mold 30 for making a windshield assembly in accordance with the present invention. The mold 30 is formed of a lower section 31 and an upper section 32 (half of which has been cut away along a center line 33 for illustration purposes). While the mold sections 31 and 32 are typically formed of a metallic material such as steel or aluminum, for example, other types of substantially non-resilient, rigid material can be used. Suitable means, not shown, are provided to open and close the mold sections 31 and 32. Also, each of the mold sections 31 and 32 can be provided with passageways (not shown) for circulating a suitable coolant through the respective mold sections.