U.S. patent application number 10/060501 was filed with the patent office on 2002-05-30 for weatherseal having a contact layer with thermoplastic particles in a thermoset carrier.
Invention is credited to Gopalan, Krishnamachari, Janes, Dennis W., Utterback, Kevin Dale, Watts, Jason O..
Application Number | 20020064660 10/060501 |
Document ID | / |
Family ID | 26786989 |
Filed Date | 2002-05-30 |
United States Patent
Application |
20020064660 |
Kind Code |
A1 |
Janes, Dennis W. ; et
al. |
May 30, 2002 |
Weatherseal having a contact layer with thermoplastic particles in
a thermoset carrier
Abstract
A weatherseal for repeatedly and releasably contacting a panel
to provide a weather resistant seal therebetween. The weatherseal
includes a substrate having a contact layer on the portion of the
substrate that contacts the panel. The contact layer includes a
multitude of surface treated ultra high molecular weight olefinic
particles, such as ultra high molecular weight polyethylene, in a
thermoset material such as cross linkable urethane, wherein some of
the embedded particles define the area of contact between the
weatherseal and the panel.
Inventors: |
Janes, Dennis W.; (Hamilton,
IL) ; Watts, Jason O.; (Fort Madison, IA) ;
Utterback, Kevin Dale; (Warsaw, IL) ; Gopalan,
Krishnamachari; (Knoxville, TN) |
Correspondence
Address: |
Stephen B. Salai, Esq.
Harter, Secrest & Emery LLP
1600 Bausch & Lomb Place
Rochester
NY
14604-2711
US
|
Family ID: |
26786989 |
Appl. No.: |
10/060501 |
Filed: |
January 30, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10060501 |
Jan 30, 2002 |
|
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|
09338094 |
Jun 23, 1999 |
|
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60093080 |
Jul 16, 1998 |
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Current U.S.
Class: |
428/424.8 ;
428/122; 428/327; 428/424.2 |
Current CPC
Class: |
Y10T 428/31938 20150401;
Y10T 428/31855 20150401; Y10T 428/31587 20150401; Y10T 428/31931
20150401; Y10T 428/25 20150115; B60J 10/17 20160201; Y10T 428/31573
20150401; Y10T 428/24198 20150115; Y10T 428/254 20150115 |
Class at
Publication: |
428/424.8 ;
428/327; 428/424.2; 428/122 |
International
Class: |
B32B 027/40 |
Claims
In the claims:
1. A weatherseal for releasably contacting a panel, comprising: (a)
a substrate; and (b) a contact layer on at least a portion of the
substrate, the contact layer including a thermoset carrier and a
multitude of UHMW polyethylene particles having a polar functional
group, the UHMW polyethylene particles chemically bonded to the
thermoset carrier.
2. The weatherseal of claim 1, wherein the thermoset carrier
includes cross linkable urethane.
3. The weatherseal of claim 1, wherein the substrate includes one
of an EPDM, modified EPDM, thermoplastic and thermoplastic
elastomer.
4. A weatherseal, comprising: (a) a substrate formed of one of
EPDM, modified EPDM, thermoplastic and thermoplastic elastomer; and
(b) a contact layer on the substrate, the contact layer including
surface treated UHMW polyolefin particles in a cross linked
urethane based carrier.
5. The weatherseal of claim 4, wherein the ultra high molecule
weight polyolefin particle is cross linked.
6. A contact layer for a weatherseal, comprising: (a) a multitude
of surface treated thermoplastic particles bonded to a curable
carrier.
7. The contact layer of claim 6, wherein the thermoplastic
particles are an ultra high molecular weight olefin.
8. The contact layer of claim 6, wherein the thermoplastic
particles are surface treated UHMW polyethylene.
9. The contact layer of claim 6, wherein the carrier includes
urethane.
10. The contact layer of claim 6, wherein the thermoplastic
particles have a melting temperature greater than a curing
temperature of the thermoset carrier.
11. A weatherseal, comprising: (a) a substrate; and (b) a contact
layer on a portion of the substrate, the contact layer having a
multitude of surface treated olefinic particles in a cured
thermoset urethane based carrier.
12. The weatherseal of claim 11, wherein the substrate is one of an
EPDM, a modified EPDM, a thermoplastic and a thermoplastic
elastomer.
13. The weatherseal of claim 11, wherein the surface treated
olefinic particles are UHMW polyethylene.
14. The weatherseal of claim 11, wherein the surface treated
olefinic particles are chemically bonded to the cured thermoset
urethane based carrier.
15. The weatherseal of claim 11, wherein the surface treated
olefinic particles are cross linked.
16. The weatherseal of claim 11, wherein the surface treated
olefinic particles are sufficiently bonded to the carrier to
substantially preclude separation.
17. The weatherseal of claim 11, wherein the surface treated
olefinic particles are encapsulated within the carrier.
18. The weatherseal of claim 11, wherein the surface treated
olefinic particles have a polar functional group.
19. The weatherseal of claim 11, wherein a melting temperature of
the surface treated olefinic particles is less than a curing
temperature of the urethane based carrier.
20. A method of forming a weatherseal, comprising: (a) forming a
substrate; (b) mixing a multitude of surface treated olefinic
particles and a curable thermoset urethane based carrier; (c)
disposing the mixed surface treated olefinic particles and the
curable thermoset urethane based carrier on a portion of the
substrate; and (d) curing the curable thermoset urethane based
carrier as it is disposed on the substrate to retain discrete
surface treated olefinic particles.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a weatherseal for
releasably contacting a panel, and more particularly, to a
weatherseal for releasably contacting a glass panel in an
automobile, wherein the weatherseal includes a contact layer with a
reduced coefficient of friction for allowing the glass panel to be
smoothly moved into and out of contact with the weatherseal, while
reducing passage of water or air between a seated glass panel and
the weatherseal. Specifically, the present weatherseal includes a
thermoset, thermoplastic or combined substrate having a contact
layer for contacting a panel, wherein the contact layer includes a
multitude of surface treated thermoplastic particles in a thermoset
material.
BACKGROUND OF THE INVENTION
[0002] Many vehicles employ windows formed of glass panels, wherein
the window is moveable relative to a portion of the vehicle. A
common construction includes the use of a glass panel in a door,
wherein the door and the glass panel move relative to the remainder
of the vehicle, and the glass panel moves relative to the door. In
this construction, the glass panel is frequently moved between an
open position and closed position with respect to the door and/or a
portion of the vehicle frame. Increased business transactions such
as restaurant, banking and pharmacy services are now regularly
offered in a drive-through format. These transactions require the
repeated release and engagement of the glass panel and vehicle. The
repeated opening and closing of the glass panel places significant
stress on the seal between the glass panel and the vehicle.
[0003] Traditionally, a weatherseal is employed at the interface
between the glass panel and the vehicle door and/or the vehicle.
The interface between the weatherseal and the glass panel must be
sufficient to substantially preclude the penetration of water and
air along the periphery of the glass panel, while still permitting
ready engagement and disengagement of the glass panel without
requiring significant force.
[0004] Conventional sealing structures include a soft synthetic
resin or synthetic rubber. However, such weatherseals do not
provide for the ready opening and closing of the glass panel
relative to the seal. Further this structure often presents
difficulty in securing of the door relative to the vehicle.
Further, a large force is loaded on the window glass during opening
or closing.
[0005] Therefore, the need exists for a weatherseal that has
reduced force requirements for moving a glass panel into and out of
engagement with the weatherseal. The need also exists for a
weatherseal having enhanced wear capabilities. A need also exists
for a method of forming a low friction weatherseal.
SUMMARY OF THE INVENTION
[0006] The present invention provides a weatherseal for repeatedly
releasably contacting a panel, wherein the weatherseal has a
reduced coefficient of friction between the weatherseal and the
panel, while providing enhanced sealing characteristics. The
weatherseal of the present invention also provides enhanced
durability in terms of engagement/disengagement cycles.
[0007] Generally, the present weatherseal includes a substrate
having a contact layer on a portion of the substrate, wherein the
contact layer includes thermoplastic particles, at least partially
embedded in a thermoset material. In one configuration, the
thermoplastic particles are chemically bonded to the thermoset
material. In a preferred configuration, the thermoplastic particles
are ultra high molecular weight "UHMW" polyethylene and the
thermoset material is a cross linked urethane. In a further
configuration, the UHMW polyethylene particles are surface treated
with reactive gasses prior to mixing with the urethane. It is also
contemplated that the contact layer may be formed on only a portion
of the weatherseal and that the contact layer may be formed as a
layer.
[0008] The present invention contemplates the manufacture of a
weatherseal by treating thermoplastic particles such as UHMW
polyethylene or with reactive gasses, prior to combination with a
thermoset material. In a preferred construction, the thermoset
material is a cross linked urethane. The thermoplastic particles,
such as treated UHMW polyethylene particles are then mixed with the
thermoset material such as urethane and a quantity of silicone for
lubricity. A substrate formed of materials such as EPDM or TPE is
extruded and the thermoplastic particle-thermoset material mixture
is applied to the extruded substrate. The thermoset material of the
contact layer is then cured, wherein the discrete characteristic of
individual thermoplastic particles is maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a vehicle that may employ
various configurations of the present weatherseal.
[0010] FIG. 2 is perspective view of a first configuration of a
weatherseal embodying the present invention.
[0011] FIG. 3 is perspective view of a second weatherseal employing
the present invention.
[0012] FIG. 4 is a perspective view of a third configuration of
weatherseal employing the present invention.
[0013] FIG. 5 is an enlarged cross sectional view of an untreated
thermoplastic particle with unsatisfactory bonding characteristics
to a thermoset material.
[0014] FIG. 6 is an enlarged view of a surface treated
thermoplastic particle sufficiently chemically bonded to a
thermoset material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] The present weatherseal 20 is operably located between a
panel 10 and a portion of a vehicle. It is understood the panel 10
may be any of a variety of materials and does not limit the present
invention. For example, the panel 10 may be glass, metal or a
composite, which is painted, surface treated or bare. In the
operating environment, the panel 10 is brought repeatedly into and
out of engagement with the weatherseal 20. The engagement of the
panel 10 and the weatherseal 20 may result from motion of the
panel, the weatherseal or a combination of both. Generally, the
weatherseal 20 is disposed between the glass panel and a door, a
frame of the door, or a portion of a vehicle frame.
[0016] The weatherseal 20 includes a substrate 40 and a contact
layer 60, wherein the contact layer will contact the panel either
during motion of the panel relative to the weatherseal or in a
seated position of the panel.
[0017] For purposes of the present description, it is understood
that the term "thermoplastic" includes those materials that soften
under the action of heat to exhibit a melting point and solidify
upon cooling in a reversible operation. For purposes of the present
description, it is understood that the term "thermoset" includes
those materials that are in an inflexible state and under the
application of heat do not reach a melting point.
[0018] The present weatherseal is described in terms of the
substrate 40 and the contact layer 60 on the substrate. It is
understood that the contact layer 60 may be located on only a
portion of the substrate 40.
[0019] The substrate 40 may be formed from a variety of materials
including thermoset, and thermoplastic materials as well as
thermoplastic elastomers (TPEs). A typical thermoset material is
EPDM or a modified EPDM. As shown in FIGS. 3 and 4, the substrate
40 may include a reinforcing member 42 such as a knitted carrier, a
wire carrier, a stamped metal carrier or even a relatively rigid
material such as thermoplastic. The substrate 40 may have any of a
variety of cross sectional profiles including "C", "J", "U" or
planar. It is understood the substrate 40 may also be formed to
have a varying cross section along the length of the weatherseal
20.
[0020] The contact layer 60 is disposed on the substrate 40 and is
preferably located at those areas of contact between the
weatherseal 20 and the panel. Generally, the contact layer 60
includes a multitude of thermoplastic particles 62 in a thermoset
carrier 64, wherein the multitude of particles have a melting
temperature greater than a curing temperature of the carrier. In a
first configuration, the particles 62 are ultra high molecular
weight (UHMW) olefinic particles and the carrier 64 is a cross
linkable urethane.
[0021] The carrier 64 is a thermoset material disposed on the
substrate 40 and subsequently cured (cross linked). A suitable
material for the carrier 64 is a urethane base having a catalyst
and silicone to provide enhanced lubricity. A particular material
for the carrier 64 is a cross linkable urethane solution CHEMLOK
Z320 by Lord Corporation, with a catalyst such as Z320 B to
increase lubricity and adhesion to the UHMW olefinic particles. The
carrier material has a curing temperature at which the material
becomes cross linked and thermoset. In one configuration, the
carrier 64 sufficiently bonds to the substrate 40 to obviate the
need for intermediate adhesives.
[0022] The UHMW olefinic particles 62 are embedded in the thermoset
carrier 64 so as to be bonded to the carrier and hence the
substrate 40. Preferably, the UHMW olefinic particles 62 are
chemically bonded to the thermoset material of the carrier 64.
[0023] In the contact layer 60, the UHMW olefinic particles 62 may
be UHMW polypropylene and the thermoset material 64 may be a cross
linked urethane. The contact layer 60 may have a thickness ranging
from approximately 10 to approximately 300 microns. The thickness
of the contact layer 60 is at least partially determined by the
intended operating environment of the weather seal 20. Generally,
the greater the required flexibility of the seal 20 or the greater
the amount flexure imparted to the contact layer, the thinner the
contact layer 60. A preferred thickness of the contact layer 60 is
approximately 20 microns to approximately 50 microns.
[0024] The UHMW olefinic particles 62 may be in a size range of
approximately 20 microns to approximately 200 microns, with a
selected range of approximately 35 microns to approximately 120
microns, and a preferred range from approximately 35 microns to
approximately 65 microns. For UHMW olefinic particles 62 formed of
UHMW polyethylene, the preferred size range is from approximately
35 microns to approximately 65 microns.
[0025] The UHMW particles 62 are thermoplastic and have a melting
temperature. By controlling the molecular weight of the particles
62 and the material of the particles, the melting temperature of
the particles can be selected. Typically, molecular weights for the
UHMW olefinic material is between approximately 3 to approximately
6 million. The melting temperature of the UHMW olefinic particles
62 is selected to exceed the curing temperature of the carrier
64.
[0026] UHMW olefinic particles 62 such as VISTAMER.TM. surface
modified particles by Composite Particles, Inc. of Allentown, Pa.
have been found suitable. The surface treatment in the VISTAMER
particles results in permanent changes to the structure and
properties of the polymer surface without sacrificing the desirable
properties. The surface treated UHMW olefinic material and
particularly the UHMW PE have been impacted polar functional groups
of the particles, which results in high surface energy.
[0027] In the contact layer 60, the UHMW olefinic particles 62 are
at least partially embedded within the thermoset carrier 64. A
percentage of the thermoplastic particles 62 are entirely
encapsulated by the thermoset material 64 and a percentage of the
UHMW olefinic particles are at least partially encapsulated by the
thermoset material. Thus, the contact layer 60 has a multitude of
projections. The projections may be formed by the entirely
encapsulated or partially encapsulated UHMW olefinic particles.
[0028] It is believed the thermoset material 64 may wear from
thermoplastic (UHMW polyethylene) particles 62 at the surface of
the contact layer 60, thus exposing the UHMW olefinic material to
the panel. The modified UHMW polyethylene particles 62 are
sufficiently chemically bonded to the modified urethane 64, such
that unintended separation of the particles from the thermoset
carrier is substantially precluded. As the overlying carrier
material 64 is removed or abraded, or the overlying material
deteriorates, the UHMW olefinic particles 62 do not separation from
the carrier. Further, the stresses upon the UHMW olefinic particles
62 during engagement and disengagement with the panel do not induce
separation of the UHMW olefinic particles from the carrier.
[0029] The relative high points defined by the projecting UHMW
olefinic particles 62 (UHMW polyethylene), or the encapsulated UHMW
olefinic particles provide a reduced surface area in contact with
the panel. The projections are sufficiently sized and spaced to
maintain a seal between the contact layer 60 and the panel. The
reduced area of contact in combination with the UHMW olefinic
particles 62 and thermoset carrier 64 results in a reduced static
and dynamic coefficient of friction between the weatherseal and the
panel. In addition, both wet and dry coefficients of friction are
reduced by present configuration.
[0030] Method of Manufacture
[0031] The UHMW olefinic particles 62 are preferably formed of UHMW
polyethylene. The UHMW polyethylene may be processed from a sheet
form. Preferably, the UHMW polyethylene is ground into particles
ranging in size from approximately 35 microns to approximately 120
microns.
[0032] The UHMW polyethylene particles 62 are surface treated prior
to combination with the thermoset material of the carrier 64.
Specifically, the UHMW polyethylene particles 62 are surface
treated with reactive gases. It is believed such a treatment
induces a polarity in the previously non-polar olefins, including
UHMW polyethylene.
[0033] The treated UHMW polyethylene particles 62 are then mixed
with the modified urethane of the carrier 64 at a concentration
from approximately 0.1 percent weight to approximately 25 percent
weight, as dictated by the intended operating environment. A more
preferred range of concentrations is approximately 0.5 percent
weight to approximately 10 percent weight, wherein the most
preferred concentration ranges in from approximately 1.5 percent to
approximately 3.0 percent weight.
[0034] The substrate 40 is formed by extruding any of a variety of
materials such as EPDM, modified EPDM, thermoplastics or TPE. It is
understood the substrate 40 may be formed by any of a variety of
processes including but not limited to inject molding, extrusion or
sheeting. Preferably, the substrate 40 is formed of a thermoset
material, having a hardness of approximately 70-80 shore A. The
hardness is a parameter of the resulting structure and the desired
performance characteristics and does not limit the scope of the
invention. The substrate 40 is extruded and then vulcanized, in the
case of thermoset EPDM. Alternatively, the substrate 40 is extruded
and cooled in the case of TPE. An EPDM substrate may be treated by
either corona or with a chemical primer or by wire brushing.
However, it is preferable to select substrate materials that are
sufficiently active to adhere to the contact layer 60 to obviate
the need for these secondary procedures.
[0035] The urethane carrier 64 with the UHMW olefinic particles 62
is then applied to the substrate 40. In one configuration, the UHMW
olefinic particles and the thermoset carrier material urethane are
applied by a spray application. Thus, the UHMW olefinic particles
and the thermoset carrier material are disposed on a desired
portion of the substrate 40.
[0036] In the configuration employing cross linkable urethane as
the carrier material 64, the urethane is then cross linked to form
a thermoset material to which the UHMW olefinic particles are
chemically bonded. The urethane may be cross linked by any of a
variety of mechanisms such as curing in an oven at a predetermined
temperature and duration. As the melting temperature of the UHMW
olefinic particles 62 is greater than the curing temperature of the
carrier 64, the integrity of the particles is not jeopardized
during curing of the carrier. That is, the UHMW olefinic particles
discrete characteristics and retain their shape to form the
projections in the surface of the contact layer 60.
[0037] It is believed the pretreatment of the UHMW olefinic
material and particularly the UHMW polyethylene particles induces a
polarity which then results in a chemical bond between the olefinic
particles 62 and the urethane (cross linked urethane) carrier 64.
Thus, in contrast to prior devices which employ a mechanical type
of bond between particles and a carrier, the present invention
produces chemical bond between the UHMW olefinic particles 62 and
the thermoset urethane carrier 64. The chemical bond provides an
enhanced retaining force on the UHMW olefinic particle 62. Thus,
the present UHMW olefinic particles 62 substantially resist
separation from the thermoset carrier during installation or use of
the weatherseal 20. As the weatherseal 20 is stressed during
formation, installation or use, the UHMW olefinic particles 62
remain bonded to the carrier 64 and hence the substrate 40.
[0038] In addition, it has been found that the use of the particles
reduces noise generation upon relative movement between the panel
and the weatherseal.
[0039] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiments, it is to be understood that the invention is not to be
limited to the disclosed embodiment, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the appended claims, which
scope is to be accorded the broadest interpretation so as to
encompass all such modifications and equivalent structures.
* * * * *