Description:FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION
A SEALING ASSEMBLY FOR A VEHICLE DOOR AT HEADER AREA

2. APPLICANTS

NAME : ALP Nishikawa Company Private Limited
NATIONALITY : IN
ADDRESS : Plot No. 32 (HUDA), Sector-18, Gurugram-122015, Haryana, India

2. PREAMBLE TO THE DESCRIPTION

COMPLETE

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD

[0001] The present invention, in general, relates to a sealing assembly, and more particularly, to a sealing assembly for a vehicle door at header area to enhance sealing efficiency, improve overall noise, vibration, and harshness (NVH) performance, and articulation index of the vehicle.

BACKGROUND
[0002] In modern vehicles, a sealing assembly plays an important role in an overall performance and comfort of the vehicle. When applied to a vehicle door, the sealing assembly ensures a tight interface between the vehicle door and body side outer (BSO) to prevent entry of external elements such as water, dust, and wind. This prevention is essential for maintaining a clean and safe interior environment and also for safeguarding sensitive electronic components and upholstery within the vehicle.
[0003] The sealing assembly also controls noise, vibration, and harshness (NVH). By dampening vibrations and reducing air leaks, the sealing assembly minimizes entry of road noise, wind noise, and structural vibrations into the vehicle cabin, thereby improving passenger comfort and enhancing driving experience.
[0004] In a conventional arrangement, the sealing assembly is fixed on the door perimeter, which comes into contact with the BSO when the door is closed, thereby providing a sealing function. While this arrangement is effective at lower speeds, it encounters limitations at higher speeds.
[0005] At high speed, aerodynamic forces act on the vehicle door, creating an outward suction effect that causes the vehicle door to move slightly away from the body structure. As a result, small gaps may form, enabling wind turbulence, external noise, dust, and water to enter into the vehicle cabin. Such entrance not only reduces acoustic comfort but also negatively affects the vehicle’s NVH performance.
[0006] A number of sealing assemblies are known for sealing the vehicle doors at header area, one of such conventional assemblies is a single-lip sealing assembly. However, at high speeds, the single-lip sealing assembly is not able to provide effective sealing.
[0007] With increasing demand for quiet, comfortable, and refined cabins, there is an industry-wide need to improve sealing performance in order to achieve better insulation, reduce NVH issues, and maintain overall sealing integrity even under high-speed conditions.
[0008] In light of the foregoing discussion, there exists a need to address this problem by providing an improved sealing assembly for vehicle doors at header area that ensures improved NVH and articulation index, and better appearance.

SUMMARY

[0009] The present invention provides a sealing assembly for a vehicle door at a header area. The sealing assembly includes a base member. The base member is configured to be mounted along the header area of the vehicle door. The sealing assembly further includes a sealing element. The sealing element is configured to be extended from the base member. In an embodiment, the sealing element includes a first sealing lip and a second sealing lip arranged to contact a body side outer. Further, the sealing assembly includes a stiffener integrated within the sealing assembly and a fastening element for securing the base member to the vehicle door.
[0010] In an embodiment, the first sealing lip and the second sealing lip may be oriented at different angles relative to the base member to provide multi-stage sealing. The arrangement of the second sealing lip in an extrusion header area may improve articulation index, reduce noise, vibration, and harshness (NVH), and provide enhanced appearance.
[0011] In an embodiment, the base member may comprise a dense elastomeric material that provides structural support to the sealing element, while at least one of the sealing lips and the stiffener may comprise a sponge elastomeric material having a specific gravity less than 0.7.
[0012] In an embodiment, the dense elastomeric material of the base member may have a Shore A hardness higher than the sponge elastomeric material forming the sealing lips.
[0013] In an embodiment, the stiffener may be selected from a hollow tubular stiffener, a solid rectangular stiffener, or a solid square stiffener.
[0014] In an embodiment, the fastening element may comprise a clip configured to engage with a flange of the vehicle door.
[0015] In an embodiment, the second sealing lip may be configured as an aero lip to act as a barrier against airflow.
[0016] In an embodiment, the first sealing lip and the second sealing lip may differ in geometry to optimize sealing performance.
[0017] In an embodiment, the sealing assembly may further include a joint mold configured to connect with the sealing element to provide a continuous sealing structure around the vehicle door.
[0018] In an embodiment, the first and second sealing lips may be integrally formed with the base member as a unitary structure, and the base member may be adapted to distribute compressive forces across both sealing lips during closure of the vehicle door.
[0019] In another embodiment, a vehicle door may include a sealing assembly at a header area, wherein the sealing assembly includes a base member mounted along a header area, a sealing element including a first sealing lip and a second sealing lip that are arranged to contact the body side outer, a stiffener integrated within the sealing assembly, and a fastening element to secure the base member to the door.
[0020] A primary objective of the present invention is to provide a sealing assembly for a vehicle door at a header area that ensures reliable and effective sealing performance under dynamic operating conditions including high-speed driving.
[0021] A further objective of the present invention is to provide a dual-lip sealing arrangement wherein a first sealing lip and a second sealing lip are positioned at different angles to achieve multi-stage sealing.
[0022] Yet another objective of the present invention is to incorporate a dense elastomeric base member that provides structural support to the sealing element, ensuring durability, proper compression, and consistent sealing performance over the lifetime of the vehicle.
[0023] Yet another objective of the present invention is to integrate a sponge elastomeric material of gravity less than 0.7 in at least one of the sealing lips and also a sponge elastomeric material of gravity less than 0.7 in the stiffener, thereby reducing weight, enhancing flexibility, and improving the ability to maintain contact with the vehicle body during dynamic conditions.
[0024] Yet another objective of the present invention is to provide a stiffener, such as a hollow tube, a solid rectangular, or a solid square stiffener, to improve structural stability of the sealing assembly while maintaining design flexibility.
[0025] Yet another objective of the present invention is to incorporate a fastening element, such as a clip, to attach the sealing assembly to the vehicle door securely, ensuring ease of installation and long-term retention.
[0026] Yet another objective of the present invention is to include an aero-configured second sealing lip, which acts as an aerodynamic barrier to reduce airflow intrusion, improve NVH (Noise, Vibration, and Harshness) characteristics, and enhance the articulation index of the sealing system.
[0027] Yet another objective of the present invention is to ensure that the sealing assembly provides continuous sealing around the vehicle door by utilizing a joint mold connection, improving both functional performance and aesthetic appearance.
[0028] Yet another objective of the present invention is to simplify manufacturing and enhance durability of the sealing assembly for the vehicle door at the header area by providing a unitary structure in which the base member and sealing lips are integrally formed.
[0029] Yet another objective of the present invention is to provide a vehicle door incorporating the sealing assembly at a header area described herein, resulting in improved passenger comfort, noise reduction, and overall vehicle refinement
[0030] The foregoing summary is provided for illustrative purposes only and is not intended to limit the scope of the invention in any way. In addition to the illustrative aspects, embodiments, and features described earlier, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings, which are incorporated herein and constitute a part of this disclosure, illustrate exemplary embodiments, and together with the description, serve to explain the disclosed principles. The same numbers are used throughout the figures to reference like features and components, wherein:
[0032] FIG. 1 illustrates a schematic representation of a sealing assembly for a vehicle door at a header area, in accordance with one or more exemplary embodiments of the present disclosure;
[0033] FIG. 2 illustrates a pictorial representation of the sealing assembly for the vehicle door at the header area, in accordance with one or more exemplary embodiments of the present disclosure;
[0034] FIG. 3 illustrates the sealing assembly at the header area for front door of the vehicle, in accordance with one or more exemplary embodiments of the present disclosure; and
[0035] FIG. 4 illustrates the sealing assembly at the header area for rear door of the vehicle, in accordance with one or more exemplary embodiments of the present disclosure;
[0036] FIG. 5 illustrates the sealing assembly designed to provide a double sealing effect when the vehicle door is in the closed position, in accordance with one or more exemplary embodiments of the present disclosure;
[0037] FIG. 6 illustrates different configurations of the sealing assembly, including a baseline configuration, a double-lip configuration, and double-lip configurations with hollow tube and solid square stiffener, in accordance with one or more exemplary embodiments of the present disclosure; and
[0038] FIG. 7 illustrates a chart of comparison between articulation index (AI%) at different speeds, in accordance with one or more exemplary embodiments of the present disclosure.
[0039] The foregoing shall be more apparent from the following more detailed description of the disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

[0040] To be better understood by those skilled in the art, the present invention is described in the following description with reference to the attached drawings.
[0041] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that these specific details are only exemplary and not intended to be limiting.
[0042] It is to be understood that various omissions and substitutions of equivalents may be made as circumstances may suggest or render expedient to cover various applications or implementations without departing from the scope of the present disclosure.
[0043] Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of clarity of the description and should not be regarded as limiting.
[0044] Furthermore, in the present description, references to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification does not necessarily refer to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
[0045] Further, the terms “a” and “an” used herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described, which may be requirements for some embodiments but not for other embodiments.
[0046] In an automotive field, sealing plays a vital role in ensuring that a vehicle remains protected, comfortable, and efficient. It involves using specially designed seals to close off gaps, joints, and interfaces between different parts of the vehicle to block the entry or escape of elements like water, dust, air, noise, or heat. This process is crucial for preserving the structural integrity of the vehicle and enhancing the driving experience.
[0047] Automotive seals are typically made from high-quality, flexible materials such as engineered rubber or elastomeric materials. These materials are selected due to their ability to maintain elasticity over time, provide strong adhesion, and withstand harsh environmental conditions like UV rays, ozone exposure, extreme temperatures, and contact with various chemicals. These seals also serve as protective barriers for the vehicle’s components, including door panels, window frames, and structural joints. By doing so, they not only ensure a more comfortable cabin but also contribute to the overall durability and reliability of the vehicle.
[0048] A sealing assembly refers to an arrangement of sealing components that function together to provide effective protection and insulation for specific sections of a vehicle. The assembly generally includes a base member, a joint mold, sealing lips, and other related features, all of which must conform to the increasingly complex geometries of the vehicle doors. The sealing assembly is designed not only for functional performance, such as, but not limited to, keeping water and dust out and reducing wind or road noise, but also to meet aesthetic and aerodynamic goals, contributing to the overall quality perception of the vehicle.
[0049] The sealing assemblies are generally applied around critical openings of the vehicle, including edges of vehicle doors, windows, trunks, and similar openings, to prevent ingress of water, dust, and noise.
[0050] Referring to FIG. 1, a pictorial representation of the sealing assembly for the vehicle door at a header area is disclosed.
[0051] As depicted, the sealing assembly (100) includes a plurality of components to provide effective sealing and durability. The sealing assembly (100) includes a base member (102). The base member (102) is configured to be mounted along the header area of the vehicle door. In one embodiment, the base member (102) comprises a dense elastomeric material to provide a structural support to sealing element. The dense elastomeric material ensures proper retention of the sealing element under dynamic conditions such as door closing impacts, vibration, high vehicle speed and temperature variations.
[0052] In an exemplary embodiment, the dense elastomeric material of the base member (102) may possess a Shore A hardness suitable for maintaining its shape while allowing controlled flexibility. The dense elastomeric material forming the base member (102) may be selected from a group of high-performance elastomers, such as Ethylene Propylene Diene Monomer (EPDM), Thermoplastic Elastomer (TPE), or silicone-based compounds. These materials provide excellent resistance to environmental factors such as UV exposure, ozone degradation, moisture, and temperature fluctuations. In an exemplary embodiment, an EPDM dense 70 Shore A is utilized in the base member.
[0053] In an alternative embodiment, the base member (102) may be co-extruded with different materials to create a composite profile, where a harder core provides structural support, and a softer outer layer improves sealing compliance and ease of installation.
[0054] It is important to note that the base member (102) forms a robust structure for the sealing element, ensuring reliable performance under a wide range of operating conditions while accommodating design flexibility for various vehicle configurations.
[0055] The sealing assembly (100) further includes a sealing element (104). The sealing element (104) is designed to ensure effective sealing under a wide range of operating conditions, including dynamic movement, and exposure to environmental factors such as wind, water, and dust. The sealing element (104) is configured to be extended from the base member (102).
[0056] In an embodiment, the sealing element (104) includes a first sealing lip (104a) and a second sealing lip (104b). The first and second sealing lips are configured to provide a sealing interface between the vehicle door and body side outer (BSO). The arrangement of these two distinct sealing lips creates a multi-stage sealing effect, preferably a two-stage sealing, where the first lip provides an initial barrier against external elements, while the second lip forms a secondary, reinforced seal to prevent any residual ingress of air, noise, or contaminants.
[0057] In an embodiment, the sealing lips (104a) (104b) are strategically positioned to engage with the BSO when the vehicle door is closed. For example, the first sealing lip (104a) and the second sealing lip (104b) are oriented at different angles relative to the base member (102) to provide multi-stage sealing. The first lip (104a) may be angled to provide an initial contact for pre-compression sealing, while the second lip (104b) may be oriented at a steeper angle to deliver firm compression against the BSO during full closure. This multi-angle arrangement enhances the overall sealing performance, particularly under varying door tolerances and high-speed aerodynamic loads.
[0058] Further, the first sealing lip (104a) and the second sealing lip (104b) may have different geometries to optimize sealing performance.
[0059] In an embodiment, the first sealing lip (104a) and the second sealing lip (104b) are integrally formed with the base member (102) as a unitary structure. Alternatively, one or both lips may be formed as separate components bonded to the base member (102) to allow for the use of different materials or geometries tailored for specific sealing zones.
[0060] In an embodiment, the first and second sealing lips are made from the same sponge elastomeric material to ensure uniform sealing characteristics, while the base member (102) provides the necessary structural support through a denser elastomeric composition.
[0061] It is important to note that at least one of the sealing lips comprises a sponge elastomeric material with a gravity less than 0.7. In an exemplary embodiment, at least one of the sealing lips comprises the sponge elastomeric material of specific gravity of 0.6. The use of sponge elastomer provides excellent compressibility, reduced closing effort, and enhanced noise attenuation. Suitable materials for the sponge elastomer may include EPDM sponge, silicone sponge, or thermoplastic elastomer sponge, all of which exhibit excellent environmental resistance to UV light, ozone, moisture, and temperature extremes.
[0062] In another embodiment, the first lip (104a) may comprise a soft sponge elastomer for improved initial compression, while the second lip (104b) may include a denser or hybrid material for reinforced sealing performance.
[0063] In an embodiment, one of the sealing lips, typically the second sealing lip (104b), may be configured as an aerodynamic lip (aero lip) to act as a barrier against airflow, reducing aerodynamic noise and turbulence at high speeds. In an exemplary embodiment, the aero lip may include a tapered or curved geometry that directs airflow away from the sealing interface, further improving noise, vibration, and harshness (NVH) characteristics of the vehicle.
[0064] It is important to note that the sealing element (104) is designed to maintain long-term durability under repeated door openings and closings.
[0065] The sealing assembly (100) further includes a stiffener (which is shown in the FIG.5). In an embodiment, the stiffener is integrated within the sealing assembly (100) to enhance structural stability. In an embodiment, the stiffener comprises a sponge elastomeric material having a specific gravity of less than 0.7. In an exemplary embodiment, the stiffener comprises the sponge elastomeric material having a specific gravity of 0.6.
[0066] The stiffener may be selected from a hollow tube stiffener or a solid rectangular stiffener, or a solid square stiffener.
[0067] The sealing assembly (100) further includes a fastening element (106). The fastening element (106) is configured for securing the base member (102) to the vehicle door. In an exemplary embodiment, the fastening element (106) is implemented as a clip. This clip is configured to engage with a flange of the vehicle door.
[0068] It is important to note that the flange forms part of the door’s inner metal frame and acts as a mounting surface for the sealing assembly. The clip may enable quick and secure installation without the need for additional tools or adhesives. This not only reduces assembly time but also enables easier replacement or maintenance of the sealing assembly when required.
[0069] In an exemplary embodiment, the clip may be formed from materials such as high-strength plastic to ensure durability, corrosion resistance, and sufficient flexibility for snap-fit engagement. Alternatively, metallic clips such a stainless steel or spring steel may be used for requiring higher tensile strength or in environments exposed to extreme temperatures.
[0070] In alternative embodiments, the fastening element (106) may be other than clips, such as adhesive strips, screws, or push-pin fasteners, depending on the design requirements of the vehicle door and the desired sealing performance.
[0071] By securely attaching the base member (102) to the vehicle door via the fastening element (106), the sealing assembly (100) maintains proper positioning, ensuring that the sealing lips remain consistently aligned with the body side outer. This secure attachment is critical for achieving optimal sealing performance, reducing noise, vibration, and harshness (NVH), and preventing the ingress of dust, water, or air into the vehicle cabin.
[0072] Referring to FIG. 2, a pictorial representation of the sealing assembly (100) for the vehicle door at the header area is disclosed.
[0073] As depicted, the sealing assembly includes dual sealing lips (104a) (104b). These sealing lips (104a) (104b) are configured to compress against the body side outer when the door is closed, thereby forming a double-seal effect. This dual-seal arrangement improves the NVH characteristics by minimizing wind noise and preventing the ingress of air, dust, and water into the passenger cabin. The base member (102) is designed to effectively distribute compressive forces across both sealing lips during closure of the vehicle door to ensure consistent sealing performance.
[0074] Referring to FIG. 3, the sealing assembly at the header area for the front door of the vehicle is disclosed.
[0075] As depicted, the sealing element comprises a first sealing lip (104a) and a second sealing lip (104b), each extending from a base member (102). The sealing element further includes a sealing bulb (308) which connects to a joint mold (302).
[0076] In one embodiment, the joint mold (302) is configured to provide a continuous sealing path around the perimeter of the front vehicle door, ensuring uninterrupted sealing in the header area, where the front door panel (304) closes against the body side outer (306). The joint mold (302) is strategically positioned between the front door panel (304) and the body side outer (306), thereby ensuring a seamless transition of the sealing profile around the corner region.
[0077] Additionally, the base member (102) is further coupled with a sealing strip (310) that interfaces with the door inner panel, thereby enhancing sealing integrity at the inner side.
[0078] By maintaining uniform compression along the sealing lips (104a, 104b), the sealing bulb (308), and the joint mold (302) when the door is shut, the assembly improves sealing efficiency, reduces potential leakage points, and enhances NVH (Noise, Vibration, and Harshness) performance of the vehicle cabin.
[0079] Referring to FIG. 4, the sealing assembly at the header area for rear door of the vehicle is disclosed.
[0080] As depicted, the sealing element comprises the first sealing lip (104a) and the second sealing lip (104b), each projecting from a base member (102). The sealing element further incorporates the sealing bulb (408) connected to the joint mold (402).
[0081] In one embodiment, the joint mold (402) extends along the rear door perimeter and is configured to provide continuous sealing, particularly in the header area, where the rear door panel (404) closes against the body side outer (306). The joint mold (402) is arranged between the rear door panel (404) and the body side outer (306). The base member (102) is further coupled with the sealing strip (410) that interfaces with the rear door inner panel, thereby reinforcing sealing effectiveness at the inner side
[0082] Referring to FIG. 5, the sealing assembly designed to provide a double sealing effect when the vehicle door is in the closed position is disclosed.
[0083] As depicted, the sealing assembly includes the first sealing lip (104a) that contacts the body side outer (306) to form the first barrier against external elements such as water, dust, and wind. The second sealing lip (104b) is positioned inward of the first sealing lip (104a) and engages the body side surface to create an additional sealing line, thereby enhancing the overall sealing performance and providing redundancy in case of the first sealing lip failure.
[0084] Referring to FIG. 6, different configurations of the sealing assembly, including a baseline configuration, a double-lip configuration, and double-lip configurations with hollow tube stiffener and solid rectangular stiffener are illustrated, in accordance with one or more exemplary embodiments of the present disclosure.
[0085] As illustrated, the baseline configuration shows conventional single-lip sealing assembly used in the vehicle door. This configuration lacks the second sealing lip to act as an additional barrier against airflow, which limits its effectiveness in providing consistent sealing under dynamic conditions such as high-speed driving or varying pressure loads.
[0086] The second illustration depicts a sealing assembly with a double-lip sealing element. The additional lip creates a secondary barrier against air, dust, and noise infiltration, thereby enhancing sealing efficiency compared to the baseline. This design improves NVH characteristics by reducing wind noise.
[0087] The third configuration “double lip with hollow stiffener” adds a hollow stiffener pad within the bulb section of the double-lip seal. This stiffener increases structural stability while maintaining flexibility. The hollow design ensures the sealing element can absorb compressive forces effectively without becoming overly rigid, thereby maintaining optimal contact pressure with the body side outer.
[0088] The fourth configuration incorporates a solid rectangular stiffener. This design provides maximum reinforcement to the sealing structure, preventing deformation under aerodynamic suction forces. It enhances the compression load distribution across the sealing interface, ensuring reliable sealing even at higher vehicle speeds.
[0089] Referring to FIG. 7, a chart of comparison between articulation index (AI%) at different speeds is illustrated, in accordance with one or more exemplary embodiments of the present disclosure.
[0090] As depicted in FIG. 7, the results of testing various door seal configurations at different speeds are depicted, specifically measured by the Articulation Index (AI%) at the driver’s seat. AI% is a measure of speech intelligibility inside the cabin. It is important to note that higher values indicate better acoustic comfort and reduced wind noise intrusion.
[0091] The bar chart depicts comparison of AI% across different speeds (100, 120, 140, and 160 km/h) for each testing iterations against benchmark vehicle (Ford Endeavor). There are four testing iterations:
S. No. Testing Iteration Configuration
1 Baseline Baseline
2 Iteration 1 Double Lip
3 Iteration 2 Double Lip with hollow tube stiffener
4 Iteration 3 Double Lip with solid square stiffener

[0092] As depicted, At 100 km/h:
Baseline: ~78.6%
Iteration 1 (Double Lip): ~78.7%
Iteration 2 (Double Lip + Hollow Tube Stiffener): ~82.2%
Iteration 3 (Double Lip + Solid Square Stiffener): ~79.8%
Ford Endeavor Benchmark: ~83.3% (Highest)
[0093] At 120 km/h:
Baseline drops to ~65.4%,
Iteration 1 at ~65.5%, while Iteration 2 at ~68.9%, closer to the benchmark’s ~70%.
Iteration 3 also improves over baseline (~66.8%).
Ford Endeavor Benchmark: (~69.1%).
[0094] At 140 km/h:
Baseline: ~53.1%, Iteration 1 at ~53.4%, Iteration 2 at ~55.5%, and Iteration 3 at ~55.2%, Ford Endeavor Benchmark at ~58.7%,
[0095] At 160 km/h:
Baseline is lowest at ~43.8%, while Iteration 1 reaches ~44.2%, Iteration 2 reaches ~44.8%, Iteration 3 reaches ~45.2%, and Ford Endeavor Benchmark at ~47.7%.
[0096] It can be concluded that the articulation index of the baseline (Z247 vehicle) measured at driver seal found 1-3% lower than Ford Endeavor.
[0097] The Double Lip Seals (Iteration 1) significantly improve noise isolation over baseline at all speeds. Hollow Tube Stiffener (Iteration 2) offers the best improvement at moderate speeds (100–120 km/h) by maintaining consistent seal compression. Square Stiffener Pad (Iteration 3) provides the best high-speed performance (140–160 km/h), reducing leakage and enhancing NVH.
[0098] Overall, Iterations 2 & 3 together show 1–4% improvement in AI% over baseline, reducing cabin wind noise and enhancing passenger comfort.
[0099] Advantages of the Invention:
[0100] Enhanced Sealing Performance: The use of dual sealing lips oriented at different angles ensures a multi-stage sealing effect and provides protection against air, dust, water, and noise ingress compared to conventional single-lip designs.
[0101] Improved NVH (Noise, Vibration, and Harshness) Characteristics: The additional sealing lip configured as an aero lip reduces wind noise at high speeds and minimizes vibration transmission, resulting in a more comfortable cabin environment.
[0102] Superior Structural Support and Durability: The dense elastomeric base member offers robust structural support to the sealing element, maintaining consistent sealing pressure over the vehicle’s lifespan and withstanding repeated door operations without degradation.
[0103] Lightweight and Efficient Design: Incorporating a sponge elastomeric material with low specific gravity in the sealing lips and stiffener reduces overall weight while maintaining high flexibility and sealing effectiveness.
[0104] Optimized Load Distribution: The base member’s ability to distribute compressive forces across both sealing lips ensures uniform contact with the body side outer, improving long-term sealing reliability.
[0105] Stiffener Integration: The option to include hollow tube or solid rectangular, or solid square stiffeners allows the assembly to be tailored for varying structural and performance requirements, enhancing adaptability for different vehicle models.
[0106] Secure and Reliable Attachment: The fastening element with a clip design ensures easy and secure installation onto the vehicle door flange, minimizing assembly time and preventing detachment during vehicle operation.
[0107] Continuous and Seamless Sealing: The inclusion of a joint mold ensures uninterrupted sealing around the entire door perimeter, eliminating potential leakage points and contributing to consistent acoustic and environmental insulation.
[0108] Improved Aesthetic and Functional Quality: The integrated dual-lip configuration not only enhances the articulation index for better door closing effort but also contributes to an aesthetically refined vehicle appearance.
[0109] Extended Service Life and Reliability: By combining durable materials (dense elastomer for the base, sponge elastomer for the lips, and integrated stiffeners), the sealing assembly maintains its functional performance over prolonged usage, reducing maintenance needs and warranty issues.
[0110] It has thus been seen that the sealing assembly for the vehicle door according to the present invention, achieves the purposes highlighted earlier. Such a sealing assembly can in any case undergo numerous modifications and variants, all of which are covered by the same innovative concept, moreover, all of the details may be replaced by elements that are technically equivalent. The scope of protection of the invention is therefore defined by the attached claims.

Dated 17th day of September, 2025
Ankush Mahajan
Agent for the Applicant (IN/PA-1523)
OF Global Institute of Intellectual Property Pvt. Ltd.
, Claims:We Claim:
1. A sealing assembly (100) for a vehicle door at a header area, comprising:
a base member (102) configured to be mounted along the header area of the vehicle door;
a sealing element (104) extending from the base member (102), wherein the sealing element (104) comprises a first sealing lip (104a) and a second sealing lip (104b) arranged to contact a body side outer;
a stiffener integrated within the sealing assembly (100); and
a fastening element (106) for securing the base member (102) to the vehicle door.

2. The sealing assembly (100) as claimed in claim 1, wherein the first sealing lip (104a) and the second sealing lip (104b) are oriented at different angles relative to the base member (102) to provide multi-stage sealing.

3. The sealing assembly (100) as claimed in claim 1, wherein the base member (102) comprises a dense elastomeric material to provide structural support to the sealing element (104).

4. The sealing assembly (100) as claimed in claim 1, wherein at least one of the sealing lips, and the stiffener comprise a sponge elastomeric material having a specific gravity of less than 0.7.

5. The sealing assembly (100) as claimed in claim 3, wherein the dense elastomeric material of the base member (102) has a Shore A hardness higher than the sponge elastomeric material forming the sealing lips.

6. The sealing assembly (100) as claimed in claim 1, wherein the stiffener is selected from a hollow tube stiffener or a solid rectangular stiffener or a solid square stiffener.

7. The sealing assembly (100) as claimed in claim 1, wherein the fastening element (106) comprises a clip configured to engage with a flange of the vehicle door.

8. The sealing assembly (100) as claimed in claim 1, wherein the second sealing lip (104b) is configured as an aero lip to act as a barrier against airflow.

9. The sealing assembly (100) as claimed in claim 1, wherein the first sealing lip (104a) and the second sealing lip (104b) differ in geometry to optimize sealing performance.

10. The sealing assembly (100) as claimed in claim 1, wherein the sealing assembly comprises a joint mold configured to connect with the sealing element (104) to provide a continuous sealing around the vehicle door.

11. The sealing assembly (100) as claimed in claim 1, wherein the second sealing lip (104b) in extrusion header area improves articulation index, reduces noise, vibration, and harshness (NVH), and provides better appearance.

12. The sealing assembly (100) as claimed in claim 1, wherein the first sealing lip (104a) and the second sealing lip (104b) are integrally formed with the base member (102) as a unitary structure.

13. The sealing assembly (100) as claimed in claim 1, wherein the base member (102) distributes compressive forces across both sealing lips during closure of the vehicle door.

14. A vehicle door comprising a sealing assembly (100) at a header area, the sealing assembly comprising:
a base member (102) configured to be mounted along the header area of the vehicle door;
a sealing element (104) extending from the base member (102), wherein the sealing element (104) comprises a first sealing lip (104a) and a second sealing lip (104b) arranged to contact a body side outer;
a stiffener integrated within the sealing assembly (100); and
a fastening element (106) for securing the base member (102) to the vehicle door.

Dated 17th day of September, 2025
Ankush Mahajan
Agent for the Applicant (IN/PA-1523)
OF Global Institute of Intellectual Property Pvt. Ltd.