U.S. patent application number 11/536796 was filed with the patent office on 2007-02-08 for carrier assembly with fused powder and frame-warp aperture.
This patent application is currently assigned to SCHLEGEL CORPORATION. Invention is credited to William Whitehead.
Application Number | 20070028987 11/536796 |
Document ID | / |
Family ID | 35999458 |
Filed Date | 2007-02-08 |
United States Patent
Application |
20070028987 |
Kind Code |
A1 |
Whitehead; William |
February 8, 2007 |
Carrier Assembly with Fused Powder and Frame-Warp Aperture
Abstract
A carrier assembly is provided for reinforcing vehicle flange
engaging strip such as a weatherstrip or trim strip. The carrier
assembly includes a serpentine frame and a warp interlaced with the
frame to form at least one frame-warp aperture. A fused powder
bonds to at least one of the serpentine frame and the warp and
inhibits movement of the warp relative to the frame, substantially
preserving the frame-warp aperture.
Inventors: |
Whitehead; William;
(Maryville, TN) |
Correspondence
Address: |
Stephen B. Salai, Esq.;Harter, Secrest & Emery LLP
1600 Bausch & Lomb Place
Rochester
NY
14604-2711
US
|
Assignee: |
SCHLEGEL CORPORATION
111 Eighth Avenue
New York
NY
|
Family ID: |
35999458 |
Appl. No.: |
11/536796 |
Filed: |
September 29, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11054485 |
Feb 9, 2005 |
|
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11536796 |
Sep 29, 2006 |
|
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Current U.S.
Class: |
139/55.1 |
Current CPC
Class: |
D10B 2505/18 20130101;
D10B 2403/0311 20130101; B60R 13/06 20130101; D04B 21/14 20130101;
B60R 13/04 20130101; D04B 21/20 20130101; D10B 2401/062 20130101;
B60J 10/32 20160201; B60J 10/18 20160201; Y10T 428/24058
20150115 |
Class at
Publication: |
139/055.1 |
International
Class: |
D03C 13/00 20060101
D03C013/00 |
Claims
1. A method of forming a carrier assembly, the method comprising
fusing a powder to at least one of a serpentine frame and a warp to
inhibit movement of the warp relative to the frame and
substantially preserve a frame-warp aperture.
2. The method of claim 1, further comprising embedding the fused
powder frame and warp in a strip material to substantially fill the
frame-warp aperture.
3. The method of claim 1, further comprising employing a flowable
material as the powder.
4. The method of claim 1, further comprising employing a
particulate material as the powder.
5. The method of claim 1, further comprising interlacing the warp
to the frame.
6. The method of claim 1, further comprising knitting the warp to
the frame.
7. The method of claim 1, further comprising weaving the warp to
the frame.
8. The method of claim 1, further comprising crocheting the warp to
the frame.
9. The method of claim 1, further comprising heat fusing the powder
to a junction of the frame and the warp.
10. The method of claim 1, further comprising fusing a sufficient
amount of powder to at least partially coat the frame and the
warp.
11. The method of claim 1, further comprising forming the frame
with a plurality of limbs interconnected at alternate ends by
connecting regions, and the warp extends transverse to the limbs
along a longitudinal dimension of the serpentine frame.
12. The method of claim 11, further comprising forming the
interconnecting regions as linear.
13. The method of claim 11, further comprising forming the
interconnecting regions as curvilinear.
14. The method of claim 11, further comprising forming the
interconnecting regions as segmented.
15. The method of claim 11, further comprising forming the limbs to
include an inflection point.
16. The method of claim 11, further comprising forming the limbs to
be linear.
17. The method of claim 11, further comprising forming the limbs to
be curvilinear.
18. The method of claim 1, further comprising forming the powder of
one of a thermoplastic and a thermoset.
19. The method of claim 1, further comprising fusing the powder to
form a discontinuous surface on the serpentine frame.
20. The method of claim 1, further comprising fusing the powder to
form a discontinuous surface on the warp.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Division of U.S. application Ser. No.
11/054,485, filed Feb. 9, 2005, entitled Carrier Assembly with
Fused Powder and Frame-Warp Aperture and is expressly incorporated
by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A "SEQUENCE LISTING"
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to a carrier assembly for
reinforcement of a vehicular strip such as a finishing strip, a
trim strip or a sealing strip. More particularly, the present
invention relates to a carrier assembly having a serpentine frame,
a warp connected to the frame so as to define a frame-warp
aperture, wherein movement of the warp relative to the serpentine
frame is inhibited by a fused powder on at least one of the frame
and the warp, and at least a substantial portion of the frame-warp
aperture is preserved.
[0006] 2. Description of Related Art
[0007] Wire carriers are used as a reinforcing frame for extrusion
products, such as motor vehicle strips. The wire carriers typically
include a continuous wire weft formed into a zig-zag shape with
warp threads on the limbs. During manufacture of the motor vehicle
strips, the wire carrier is passed through an extruder and is thus
subjected to stresses and temperatures which can cause the warp
threads to drift laterally, stretch longitudinally and degenerate.
Such processing of the wire carrier can result, for example, in
breakage of the warps and distortion of the wire carrier which
affects the subsequent extrusion process and leads to reduced
quality and performance of the resulting vehicular strip. In the
forming and extrusion processes, drifting of the warp threads can
cause air bubbles and exposure of the wire in the final product. In
addition, the shifting of the warp threads can lead to unbalanced
locations of the warp threads in the resulting vehicular strip,
which can lead to the strip "laying over" upon installation on a
vehicle.
[0008] In addition, movement of the warp threads during the
extrusion process can impart a spiral to the resulting vehicular
strip. The tendency of the vehicular strip to spiral significantly
hinders installation of the strip on a vehicle. Further, unintended
redistribution of the warp threads can lead to a "hungry horse"
appearance in the resulting strip as the wire produces
corresponding surface features.
[0009] There has long been a need to develop a stable wire carrier
which overcomes these problems and many attempts have been made
without complete success.
[0010] EP 0384613 discloses a knitted wire carrier in which
stitched warp threads comprise two threads of polymeric material
having different melting points such that when the melting point of
the lower melting thread is exceeded the melted thread causes the
other thread to be attached to the wire weft. This structure allows
single strands of warp thread plied with a meltable filament to be
bonded to the wire carrier wherever they are knitted.
[0011] U.S. Pat. No. 5,416,961 to Vinay discloses a knitted wire
carrier comprising at least one meltable filament laid-in into at
least two adjacent warp threads, whereby on heating, the melted
filament causes the at least two adjacent warp threads to be bonded
to the wire and/or to each other for stabilizing the resulting wire
carrier against warp drift.
[0012] In spite of these issues, the wire carrier provides
substantial benefits. Specifically, the wire carrier exhibits an
inherent flexibility about three axes, which in turn provides good
handling characteristics of the finished product. Further, in
contrast to many stamped metal and lanced and stretched metal
carriers, the wire carrier is able to bear relatively high loading,
particularly during the extrusion process. In addition, the wire
carrier has the benefit of withstanding greater flexing without
exhibiting metal fatigue.
[0013] Thus, there is a need to develop a stable wire carrier for
extruded and molded polymeric products. The need also exists for a
carrier assembly with reduced or negligible warp drift, thereby
overcoming the problems associated with warp drift.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention encompasses a carrier assembly with
stable and predictable warp locations which provide improved
consistency and quality of the carrier assembly and hence improved
consistency and quality of any subsequent vehicular strip which
incorporates the carrier assembly.
[0015] The carrier assembly includes a serpentine frame, a warp
extending along the frame, wherein the warp and the serpentine
frame define a frame-warp aperture, and a fused powder on at least
a portion of one of the frame and the warp. The fused powder
impedes movement of the warp relative to the frame and preserves at
least a substantial portion of the frame-warp aperture.
[0016] The fused powder can be located at a junction of the frame
and the warp. In an alternative configuration, the fused powder can
be located primarily on the frame. In a further configuration, the
fused powder can encapsulate at least a portion of the frame and
the warp. In each configuration, at least a substantial portion of
the frame-warp aperture is preserved.
[0017] In selected configurations, the serpentine frame is formed
from a metallic or polymeric material and defines a plurality of
limbs interconnected at alternate ends by connecting regions. The
warp can include a single or a plurality of threads or yarns
interlaced with the limbs of the serpentine frame to define
frame-warp apertures.
[0018] The fused powder is readily deposited on the serpentine
frame and the warp and can be fused to inhibit movement of the warp
relative to the frame, and particularly inhibit movement of the
warp transverse to a longitudinal dimension of the frame while
preserving the frame-warp aperture.
[0019] The carrier assembly can be formed by powder coating the
serpentine frame and an interlaced warp, interlacing the warp on a
powder coated serpentine frame or interlacing a powder coated warp
with the serpentine frame.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0020] FIG. 1 is a top plan view of a representative carrier
assembly.
[0021] FIG. 2 is a cross-sectional view of a vehicular weather
strip incorporating a configuration of the carrier assembly.
[0022] FIG. 3 is a top plan view of the serpentine frame having
parallel limbs.
[0023] FIG. 4 is a top plan view of the serpentine frame having
curvilinear limbs and connecting regions.
[0024] FIG. 5 is a top plan view of the serpentine frame having
tapered connecting regions.
[0025] FIG. 6 is a top plan view of the serpentine frame having
faceted limbs and curvilinear connecting regions.
[0026] FIG. 7 is a top plan view of the serpentine frame having a
first connecting region configuration along one edge of the frame
and a different second connecting region configuration along a
second edge of the frame.
[0027] FIG. 8 is a top plan view of the serpentine frame having
parallel limbs and a plurality warps interlaced with the frame.
[0028] FIG. 9 as a top plan view of the serpentine frame having
curvilinear shaped limbs and a plurality of warps interlaced with
the frame.
[0029] FIG. 10 as a top plan view of the serpentine frame having
curvilinear shaped limbs and a different configuration of warps
interlaced with the frame.
[0030] FIG. 11 is an enlarged cross-sectional schematic view
showing the fused powder encapsulating a portion of the serpentine
frame and the warp.
[0031] FIG. 12 is a schematic cross-sectional view of a fused
powder on a portion of the serpentine frame engaging a warp.
DETAILED DESCRIPTION OF THE INVENTION
[0032] A carrier assembly 10 in accordance with the present
invention is shown in FIG. 1. The carrier assembly 10 includes a
serpentine frame 20, at least one warp 40 and a fused powder 60 on
at least one of the frame and the warp to define at least one
frame-warp aperture 30.
[0033] Referring to FIG. 2, the carrier assembly 10 can be
incorporated into any of a variety of motor vehicle finishing
strips, trim strips or weather strips. A vehicular weatherstrip 12
embedding the carrier assembly 10 is shown in FIG. 2. It is
understood the vehicle strips can have any of a variety of
configurations for engaging a vehicle, such as a flange engaging
strip.
[0034] Serpentine Frame
[0035] The serpentine frame 20 has a plurality of transversely
extending limbs 22 interconnected at alternate ends by connecting
regions 24. The limbs 22 can be straight or curvilinear, and can
define sections that are linear, faceted, banana shaped, propeller
shaped or any combination thereof. The limbs 22 are in a generally
parallel relationship, such as adjacent limbs of FIGS. 1, 3 and 8,
or alternating limbs are parallel as shown in FIGS. 4-7 and 9-10.
The serpentine frame 20 has a width defined by the connecting
regions 24 at the end of the limbs 22.
[0036] The serpentine frame 20 can be described in terms of the
number of limbs 22 per inch (cm) and the length of the limbs. A
range for limbs per inch (limbs per cm) is typically from
approximately 4 to 12 limbs per inch (1.6 to 4.7 limbs per cm),
with a usual range of about 7 to 10 limbs per inch (2.8 to 3.9
limbs per cm), and typical lengths of the limbs (across a width of
the carrier assembly 10) range from approximately 0.5 inches (1.3
cm) to approximately 3 inches (7.6 cm).
[0037] Although the term "serpentine" frame 20 is used, the
serpentine frame is intended to encompass any frame construction,
wherein the limbs 22 and connecting regions 24 can have any of a
variety of configurations including but not limited to, linear,
curvilinear or faceted, wherein a longitudinal dimension of the
frame extends generally transverse to the limbs.
[0038] The serpentine frame 20 is formed of a filament, or a
plurality of filaments having sufficient resiliency to accommodate
repeated flexing while having sufficient strength for the filament
to retain a downstream formed shape, such as a U-shape transverse
to the longitudinal dimension of the serpentine frame. The
serpentine frame 20 can be formed of a metallic or non metallic
filament. The non metallic filament materials include, but are not
limited to plastics, elastomers, polymerics, ceramics or
composites. Metallic filament materials include but are not limited
to wires, alloys, steel, stainless steel, aluminum, galvanized
metals, as well as composites.
[0039] For purposes of description, the serpentine frame 20 is set
forth in terms of a metallic filament such as wire. However, it is
understood, the description is applicable to any type of filament
forming the serpentine frame 20.
[0040] The thickness of the wire is at least partially determined
by the intended operating environment of the resulting strip as
well as the configuration of the available extrusion tooling.
Typically, the wire has a generally circular cross-section.
However, it is understood the wire may have any of a variety of
cross-sectional profiles, such as but not limited to obround,
elliptical, faceted or triangular.
[0041] In one configuration of the wire, the wire has a diameter
between approximately 0.010 inches (0.25 mm) and 0.050 inches (1.3
mm), wherein a further construction of the wire has a diameter of
approximately 0.018 inches (0.46 mm) to 0.035 inches (0.89 mm). In
yet another construction, the wire is a low carbon steel wire or
301 stainless steel having a diameter of about 0.030 inches (0.76
mm).
[0042] Referring to FIGS. 1 and 8-10, the warp 40 extends along the
longitudinal dimension of the serpentine frame 20. The warp 40 can
include a single strand or thread, or multiple strands or threads
which can be separate or intertwined. The term "warp" is intended
to encompass each of these configurations.
[0043] The warp 40 can be secured to the serpentine frame 20 by
interlacing, which includes but is not limited to knitting or
stitching such as crocheting, sewing, weaving or threading.
Referring to FIGS. 1 and 8-10, the frame 20 and the warp 40 define
a plurality of frame-warp apertures 30. The frame-warp apertures 30
have a periphery defined by the frame 20 and the warp 40. Depending
upon the interlacing of the warp 40 and the frame 20, and the
number of warps, the frame-warp apertures 30 can have a variety of
sizes. Similarly, there can be a range in the number of frame-warp
apertures 30 as defined by the number of limbs 22 per inch (cm),
the number of warps 40 and the interlacing configuration.
[0044] In one configuration, the warp 40 encompass a portion of the
serpentine frame 20 within a crocheted stitch. The warp 40 can be
secured to the serpentine frame 20, such as with chain stitching
and the warp is pre-tensioned, for example, from approximately 0.5
to 1.0 pounds (0.22 to 0.45 Kg) per warp end, with a satisfactory
pre-tensioning of approximately 0.7 pounds (0.32 Kg). It is
understood the stitching shown in FIGS. 1 and 8-10, is
representative and that the warp 40 can engage the serpentine frame
20 by any of a variety of constructions.
[0045] Depending upon the interlacing of the warp 40 with the
serpentine frame 20, intra-warp aperture 35 can also be formed as
seen in FIG. 1. The intra-warp aperture 35 is defined by the warp
40, rather than the warp and the serpentine frame 20.
[0046] The warp 40 can be threads strands, or yarns of any of a
variety of materials, such as polymeric materials. The term
polymeric is intended to encompass a polymer based on organic or
organo-silicone chemistry. The polymer can be a synthetic resin or
a natural fiber, such as cotton. Synthetic resins are
advantageously more durable and resistant to, although not free
from, the stresses incurred during embedding, for example during
extrusion of the vehicular strip. Suitable polymeric materials for
the warp 40 include, for example polyesters, polypropylenes and
nylons, with polyesters being satisfactory. The warp threads have a
typical size of about 400 to about 3,000 denier, with a usual size
between approximately 800 denier to approximately 2,000 denier.
[0047] The fused powder 60 is located on, and bonded to at least
one of the serpentine frame 20 and the warp 40. The fused powder 60
impedes or inhibits movement of the warp 40 relative to the
serpentine frame 20 (along the transverse direction), thereby
reducing warp drift, without the fused powder occluding the
frame-warp aperture 30. In one configuration, the fused powder 60
constrains the warp 40 relative to the serpentine frame 20. The
resistance to movement of the warp 40 relative to the serpentine
frame 20 is created by contact between the warp and the fused
powder 60. It is believed the contact between the warp 40 and the
fused powder 60 can be created by the fused powder bonding to the
serpentine frame 20, the fused powder bonding to the warp, or the
fused powder bonding the warp to the serpentine frame.
[0048] The amount of contact between the fused powder 60 and the
warp 40 is sufficient to reduce or retard movement of the warp
relative to the serpentine frame 20, and particularly movement of
the warp along a length of the limb 22. The contact between the
fused powder 60 and the warp 40 can be provided by the fused powder
substantially encapsulating the serpentine frame 20 and the warp
40. Alternatively, the fused powder 60 can be bonded to the
serpentine frame 20, such as before the warp 40 is interlaced, and
thus contact the warp upon interlacing. It is also contemplated the
fused powder 60 can be primarily bonded to the warp 40.
[0049] In one configuration, the fused powder 60 is on both the
warp 40 and the serpentine frame 20 and effectively locks the warp
to a position on the frame. The amount of fused powder 60 can range
from the encapsulation of at least a portion of one of the
serpentine frame 20 and the warp 40 seen in FIG. 11, to a
discontinuous (broken) sputtering seen in FIG. 12. In all
configurations, the amount of fused powder 60 is selected to
substantially preserve the frame-warp aperture 30.
[0050] It is also contemplated the fused powder 60 can be initially
located on one of the serpentine frame 20 or the warp 40, and
subsequently remelted after interlacing the warp and the frame, so
as to bond to both the warp and the frame.
[0051] In each configuration of the carrier assembly 10, including
the configuration of the fused powder 60 encapsulating at least one
of the serpentine frame 20 and the warp 40, at least a percentage
of the total number of frame-warp apertures 30 is preserved. That
is, the fused powder 60 coats the exposed surfaces of the
serpentine frame 20 and the warp 40, without occluding all the
frame-warp apertures 30. Typically, at least 50% to 100% of the
original number of frame-warp apertures 30 is preserved. It is
understood certain configurations of the carrier assembly 10 can
preserve as few as 10% of the total number of frame-warp apertures
30. That is, some of the frame-warp apertures 30 can be occluded by
the fused powder 60, without blocking all the apertures. The
initial area of a given frame-warp aperture 30 and the amount of
fused powder 60 are factors in determining the percentage of the
original frame-warp apertures 30 that remain after application of
the fused powder 60.
[0052] Thus, the fused powder 60 can form a portion of the surface
of the serpentine frame 20 or of the serpentine frame and the warp
40, wherein at least one frame-warp aperture 30 is substantially
preserved. In the encapsulation configuration for a given
frame-warp aperture 30, the fused powder 60 slightly extends into
the frame-warp aperture, and occludes a portion of the aperture.
Typically, at least 80% of the original area of the frame-warp
apertures 30 in the carrier assembly 10 is preserved, with
configurations of the carrier assembly 10 preserving 10% to 100% of
the original area of the apertures. However, depending upon the
initial area of the frame-warp aperture 30 and the amount of fused
powder 60, a given aperture (or apertures of a certain area or
smaller) can be occluded. In such configuration, the remaining
frame-warp apertures 30 are of a sufficient area to preclude
occlusion, thereby preserving at least one frame-warp aperture.
[0053] In a further configuration, the fused powder 60 is bonded to
primarily the serpentine frame 20, with a minimal or insignificant
amount of powder bonded to the warp 40. In this configuration, the
fused powder 60 forms a rough surface on the serpentine frame 20,
as seen in FIG. 12, and does not encapsulate the frame, but rather
forms local discontinuities or areas of fused powder. The roughness
imparted by the fused powder 60 is sufficient to inhibit or impede
lateral movement of the warp 40 relative to the serpentine frame 20
and limb 22. Typically, such roughness is less than the diameter of
the warp 40. Thus, for example, the fused powder 60 can create a
surface roughness on the order of approximately 0.001 inches
(0.0025 cm) to 0.010 inches (0.0254 cm). In this configuration, the
fused powder 60 preserves a majority of the frame-warp apertures
30, and in certain constructions maintains over 90% of the total
number of frame-warp apertures 30 and over 90% of the initial area
of the frame-warp apertures of the carrier assembly 10.
[0054] Thus, a percentage of the total number of initial frame-warp
apertures 30 and a percentage of the initial total area of the
frame-warp apertures are preserved. Depending upon the
configuration of the serpentine frame 20, the warp 40 and the fused
powder 60, any of a variety of combinations of preserved number of
frame-warp apertures 30 or preserved area of the frame-warp
apertures can be provided.
[0055] Powders
[0056] The fused powder 60 can be a thermoplastic or thermoset. The
thermoplastic powders do not chemically react in a heat phase, but
rather soften and then re-solidify upon reduction of the
temperature. Thermoset powders are applied and then cured, inducing
a chemical cross-linking, thereby changing the fused powder 60 into
a form that will not remelt.
[0057] The powders to be fused can be formulated to meet a variety
of performance characteristics, including thickness, texture,
color, hardness, chemical resistance, UV resistance or temperature
resistance. The particle size of the powder can also be controlled
in response to the desired performance of the fused powder 60.
[0058] A representative thermoplastic powder is polyethylene,
having a melting point below a melting point of the serpentine
frame 20 and the warp 40. In one configuration, the thermoplastic
powder has a melting point of approximately 120.degree. C.
[0059] A thermoset powder includes a thermosetting resin and a
curing, or cross linking agent. A thermosetting resin for the fused
powder can include epoxy resins, acrylic resins, phenol resins and
polyester resins. These thermosetting resins can be used alone, or
combined together with other resins. In particular, a thermosetting
resin having an epoxy group (that is, glycidyl group), such as
epoxy resins, acrylic resins are available. These thermosetting
resins have excellent reactivity to a curing agent, even at
relatively low temperatures, for example, approximately 120.degree.
C.
[0060] A latent curing agent such as dicyandiamide, imidazolines,
hydrazines, acid anhydrides, blocked isocyanates, and dibasic acids
can be added to the resin particles as a curing promoter. The
latent curing agent is typically stable at room temperature, and
crosslinks with a thermosetting resin in a range of 140.degree. C.
to 260.degree. C. It is understood any of a variety of
cross-linking agents can be employed.
[0061] For thermoplastic or thermoset powders, an additive or a
functional material can be added to the resin particles, such as a
filler including calcium carbonate, barium sulfate or talc; a
thickener, for example silica, alumina or aluminum hydroxide; a
pigment including titanium oxide, carbon black, iron oxide, copper
phthalocyanine, azo pigments or condensed polycyclic pigments; a
flowing agent such as silicone or acrylic oligomer, for example
butyl polyacrylate; an accelerating agent such as zinc compounds; a
wax such as polyolefin; a coupling agent including silane coupling;
an antioxidant; or even an antimicrobial agent.
[0062] Suitable powders to be fused are sold by Morton Powder
Coating of Warsaw, Ind. and include DG-5001 CORVEL.RTM. BLUE
(ethylene/Acrylic), DG-7001 CORVEL.RTM. BLACK 20
(Ethylene/Acrylic), 78-7001 CORVEL.RTM. BLACK (Nylon) and 70-2006
CORVEL.RTM. YELLOW (Nylon).
[0063] It is also contemplated the fused powder 60 can be selected
to promote bonding with the embedding material of the subsequent
vehicular strip 12. In such configurations, the powder includes a
methacrylate coagent or a maleate.
[0064] Thus, the fused powder 60 can be constructed to retain the
warp 40 relative to the serpentine frame 20, preserve the
frame-warp aperture 30, bond to the embedding material of the
vehicular strip 12 and insulate the frame.
[0065] The fused powder 60 is formed by retaining unfused powder on
one of the serpentine frame 20 and the warp 40, and then fusing the
powder. The powder can be temporarily disposed on the one of the
serpentine frame 20 and the warp 40 by a variety of mechanisms
including bonding agents, friction adhesion, or electrostatic
attraction.
[0066] The bonding agents can be incorporated into the powder, or
applied to the one of the serpentine frame 20 and the warp 40 in a
desired location for the fused powder 60 prior to exposure of the
frame and the warp to the powder.
[0067] Alternatively, a surface charge is formed on the one of the
serpentine frame 20 and the warp 40, and the powder is oppositely
charged, such that upon exposure of the oppositely charged powder
to the surface charged portions of one of the frame and the warp,
the powder is temporarily adhered.
[0068] To form the necessary surface charge on the one of the
serpentine frame 20 and the warp 40, a potential is applied to the
frame. It has been found that a sufficient potential can be applied
to the serpentine frame 20 to create a charge sufficient to retain
the powder prior to fusing.
[0069] By controlling the amount of powder exposed to the
electrical potential difference between the powder and the surface
charge on the one of the serpentine frame 20 and the warp 40, the
amount of powder retained on the one of the serpentine frame 20 and
the warp 40 can be controlled. As the amount of retained powder on
the one of the serpentine frame 20 and the warp 40 at least
partially determines the thickness of the fused powder 60, the
thickness of the fused powder can thus be controlled.
[0070] Alternatively, the serpentine frame 20 and the warp 40 can
be passed through a bath, or fluidized bed of the powder to deposit
the powder on the frame and the warp. The powdered serpentine frame
20 and warp 40 can then be subject to a controlled vibration or air
jet to remove excess powder. Alternatively, the powder can be
vibrated with the serpentine frame 20 and the warp 40 to deposit
the powder. It is further contemplated that rollers can be used to
deposit the powder on the serpentine frame 20 and the warp 40.
[0071] Further mechanisms for depositing the powder onto the
serpentine frame 20 and the warp 40 include sprinkling the powder
onto the frame and the warp, or passing the frame and the warp
through a curtain of the powder. It is also contemplated the powder
can be sprayed onto the serpentine frame 20 and the warp 40. The
spray method can also involve imparting a charge to the powder,
which is then electrostatically attracted to one of the serpentine
frame 20 and the warp 40. Alternatively, a contact device, such as
a roller can also be employed to deposit the powder onto the frame
20 and the warp 40.
[0072] The temporarily retained or adhered powder is then melted
and bonded to the serpentine frame 20 by a variety of options
including radiative, convective, inductive or conductive heating.
The bonding of the fused powder 60 to the serpentine frame 20 or
the warp 40 is sufficient to inhibit movement of the warp relative
to the limb 22.
[0073] The heating can be accomplished in a processing line
downstream of the knitter (which formed the interlaced warp 40 and
the serpentine frame 20) and a finished carrier assembly 10 take-up
apparatus. Heating above the melting point of the meltable (or
curable) powder causes the powder to bond to the serpentine frame
20 and/or the warp 40. On cooling, the melted powder hardens and
the warp 40 is bonded in position. In one configuration, the warp
40 is bonded to the serpentine frame 20 and locked in a given
position. In a different configuration, the fused powder 60 forms
the roughened surface on the serpentine frame 20 which engage the
warp 40. The carrier assembly 10 has a flat profile, is
longitudinally stable and is virtually free of warp drift.
[0074] Heating of the frame, the warp and the powder can be
accomplished by a variety of methods which allow the powder to be
heated close to or above the melting point of the powder. In one
configuration, the heating above the melting point of the meltable
powder is carried out for a period of time sufficient to cause the
melted powder to at least partially flow about the junction of the
warp 40 and the serpentine frame 20. Generally, the heating of the
serpentine frame 20, the warp 40 and the powder can be accomplished
by conductive, inductive, convective or radiative heating such as
infrared, hot air or microwave. One method of heating includes
exposing the serpentine frame 20, the warp 40 and the powder to a
flow of heated air in an oven to fuse the powder without fusing or
melting the warp. Another method comprises heating the serpentine
frame 20, the warp 40 and the powder with infra-red radiation. A
further method comprises passing the serpentine frame 20, the warp
40 and the powder over a heated roller. Another method contemplates
induction heating of the serpentine frame 20. In yet another
configuration, the heated serpentine frame 20, the warp 40 and the
powder are passed between forming rolls. The roll treatment can
also help to maintain the flat profile of the carrier assembly 10.
The roll forming treatment can be applied during the heating
process or immediately after the powder is fused.
[0075] Cooling of the carrier assembly 10 is accomplished by
exposure to cooling jets or streams which can include air jets or
ambient temperatures for a period of time after pulling the carrier
assembly from the heater.
[0076] In contrast to powder coating the serpentine frame 20
interlaced with the warp 40, it is contemplated the fused powder 60
can be bonded to the filament prior to interlacing the warp 40.
That is, the fused powder 60 is bonded to the filament, and the
coated filament is formed into the serpentine frame and interlaced
with the warp 40. The fused powder 60 thus mechanically engages the
warp 40 and bonds to the serpentine frame 20.
[0077] In a further configuration, it is contemplated the fused
powder 60 can be bonded to the warp 40 prior to interlacing with
the filament.
[0078] Therefore, the process can include powder coating the
serpentine frame 20 and the interlaced warp 40, interlacing the
warp with a powder coated serpentine frame or interlacing a powder
coated warp with the serpentine frame.
[0079] It is further contemplated that for thermoplastic fused
powders 60 on one of the filament or the warp 40 prior to
interlacing, the fused powder can be reheated after interlacing to
induce the powder to fuse bond to the remaining component.
[0080] The invention provides a strong, physically and chemically
stable carrier assembly 10, essentially free of warp drift which
allows close grouping and selective positioning of adjacent warp
40, and allows grouping and bonding of different numbers of
adjacent warps. Warp damage is minimized in the subsequent
extrusion coating processes and, overall, greater control of the
profile, appearance and quality of the product is achieved. The
present process uses existing knitting equipment with a minimum of
modification and is effective in reducing manufacturing costs.
[0081] It is also contemplated the amount of fused powder 60 can be
selected to reduce or minimize de-spragging of the carrier assembly
10. That is, absent the fused powder 60, upon cutting the
serpentine frame 20, the free end of the serpentine frame 20 (the
filament) tends to straighten and can form an undesirable
projection which can interfere with subsequent operator and machine
handling of the carrier assembly 10. It is believed the fused
powder 60 can provide sufficient retentive force on the carrier
assembly 10 to substantially preclude the free end of the
serpentine frame 20 (the filament) pulling from the warp 40. Thus,
the previously required step of de-spragging the cut carrier
assembly 10 is obviated.
[0082] In addition, it is believed the fused powder 60 on the warp
40 reduces a tendency of the warp to fluff or fray upon the carrier
assembly 10 (and the warp) being cut to length. Reducing the fluff
of the cut warp 40 reduces the tendency of the carrier assembly 10
(and the warp) to absorb moisture, and improves subsequent
embedding of the carrier assembly, thereby providing a more
satisfactory finished product.
[0083] The carrier assembly 10 is particularly useful as
reinforcement for elastomeric (polymeric) vehicular strip 12 for
example, flange engaging strips including trunk seals, door seals
or edge protector strips as well as glass run channels, and sun
roof seals. The carrier assembly 10 is advantageous for extrusion
processes due to the control or virtual absence of warp drift and
longitudinal stability under the conditions of the extrusion
process. The carrier assembly 10 provides for positioning of the
warp 40 or warps, at the parts of the strip requiring the most
reinforcement, for example, the base or the sides of a subsequently
formed U-shape channel.
[0084] In subsequent formation of the vehicular strip 12 the
preserved frame-warp aperture 30 is filled by the embedding
material of the strip during a conventional extrusion or molding
processes. The material embedding the carrier assembly 10 is
typically a polymeric material, such as for example, a
thermoplastic or thermosetting elastomer. Generally, the carrier
assembly 10 is fed through an extruder, wherein a polymeric
material is extruded about the carrier assembly 10 so as to embed
the carrier assembly within the polymeric material. To provide
satisfactory embedding of the carrier assembly 10, the embedding
material must "strike through" the frame-warp aperture 30. That is,
the embedding material must flow through the frame-warp aperture
30, thereby entirely embedding the cross section of the carrier
assembly 10.
[0085] While the invention has been described in conjunction with
specific embodiments thereof, it is evident that many alternatives,
modifications, and variations will be apparent to those skilled in
the art in light of the foregoing description. Accordingly, the
present invention is intended to embrace all such alternatives,
modifications, and variations as fall within the spirit and broad
scope of the appended claims.
* * * * *