U.S. patent application number 15/886615 was filed with the patent office on 2018-06-07 for systems and methods for manufacturing reinforced weatherstrip.
The applicant listed for this patent is Amesbury Group, Inc.. Invention is credited to John E. Huntress, Peter Mertinooke.
Application Number | 20180154567 15/886615 |
Document ID | / |
Family ID | 38308645 |
Filed Date | 2018-06-07 |
United States Patent
Application |
20180154567 |
Kind Code |
A1 |
Huntress; John E. ; et
al. |
June 7, 2018 |
SYSTEMS AND METHODS FOR MANUFACTURING REINFORCED WEATHERSTRIP
Abstract
Methods for manufacturing fabric-reinforced weatherstrip include
incorporating a fabric application step into a process for making
coated substrates. In one embodiment, a strip of the fabric from a
roll of material may be applied directly onto a coating after it
has been applied in a coat die to a foam profile, while the coating
is still in the molten state. Alternatively, a fabric application
plate may be attached to an upstream side of coating die with a
fabric feed channel cut into the plate. The fabric follows the
channel to contact and mate with the foam profile. The fabric
applicator plate may be configured so as to exert pressure on only
the part of the product where the fabric is being applied.
Ultrasonic welding techniques may also be employed.
Inventors: |
Huntress; John E.;
(Brentwood, NH) ; Mertinooke; Peter; (Amesbury,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amesbury Group, Inc. |
Amesbury |
MA |
US |
|
|
Family ID: |
38308645 |
Appl. No.: |
15/886615 |
Filed: |
February 1, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15145963 |
May 4, 2016 |
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15886615 |
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12690405 |
Jan 20, 2010 |
9358716 |
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15145963 |
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11716397 |
Mar 9, 2007 |
7718251 |
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12690405 |
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60780991 |
Mar 10, 2006 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 65/562 20130101;
B29K 2105/04 20130101; B29K 2101/12 20130101; B29C 31/08 20130101;
B29C 48/16 20190201; B29C 48/355 20190201; B29L 2031/003 20130101;
B29C 65/086 20130101; B29C 66/727 20130101; B29K 2083/00 20130101;
E06B 7/2305 20130101; B29C 48/21 20190201; B29C 44/326 20130101;
B29C 48/12 20190201; B29L 2031/26 20130101; B29C 31/04 20130101;
B29C 48/155 20190201; B29K 2075/00 20130101; B29C 65/08 20130101;
B29C 66/83411 20130101; B29C 66/8432 20130101; B29C 35/02 20130101;
B29C 48/34 20190201; B29C 65/02 20130101; B29C 65/56 20130101; B29C
66/524 20130101; B29K 2055/02 20130101; B29C 48/151 20190201; B29K
2023/083 20130101; B29C 48/154 20190201; B29C 48/156 20190201; B29K
2077/00 20130101; B29C 48/09 20190201; B29C 65/62 20130101; B29C
66/73921 20130101; B29L 2031/006 20130101; B29C 66/0242 20130101;
B29C 66/83413 20130101; B29K 2023/06 20130101; Y10T 428/249953
20150401; B29K 2023/12 20130101; B29C 66/5326 20130101; B29C
66/72941 20130101; E06B 7/2314 20130101; B29C 66/71 20130101; B29K
2033/08 20130101; B29C 48/0013 20190201; B29C 66/81463 20130101;
B29C 48/304 20190201; B29C 66/73771 20130101; B29C 48/15 20190201;
B29C 63/044 20130101; B29C 66/7292 20130101; B29C 66/433 20130101;
B29C 66/71 20130101; B29K 2083/00 20130101; B29C 66/71 20130101;
B29K 2077/00 20130101; B29C 66/71 20130101; B29K 2075/00 20130101;
B29C 66/71 20130101; B29K 2067/00 20130101; B29C 66/71 20130101;
B29K 2055/02 20130101; B29C 66/71 20130101; B29K 2033/08 20130101;
B29C 66/71 20130101; B29K 2023/12 20130101; B29C 66/71 20130101;
B29K 2023/083 20130101; B29C 66/71 20130101; B29K 2023/08 20130101;
B29C 66/71 20130101; B29K 2023/0625 20130101; B29C 66/71 20130101;
B29K 2023/06 20130101; B29C 66/71 20130101; B29K 2021/003 20130101;
B29C 66/71 20130101; B29K 2021/00 20130101; B29C 66/71 20130101;
B29K 2019/00 20130101; B29C 66/71 20130101; B29K 2007/00
20130101 |
International
Class: |
B29C 47/02 20060101
B29C047/02; E06B 7/23 20060101 E06B007/23; B29C 31/04 20060101
B29C031/04; B29C 35/02 20060101 B29C035/02; B29C 44/32 20060101
B29C044/32; B29C 47/12 20060101 B29C047/12; B29C 65/08 20060101
B29C065/08; B29C 65/56 20060101 B29C065/56 |
Claims
1-25. (canceled)
26. A weatherstrip comprising: a foam profile; a stiffener in
mating contact with the foam profile; and a coating layer
substantially coating the foam profile, wherein at least a portion
of the foam profile not in mating contact with the stiffener is not
coated by the coating layer.
27. The weatherstrip of claim 26, wherein the coating layer at
least partially coats the stiffener.
28. The weatherstrip of claim 26, wherein the portion of the foam
profile not coated by the coating layer is covered by a fabric
layer.
29. The weatherstrip of claim 26, wherein the foam profile
comprises an irregular elongate shape.
30. The weatherstrip of claim 29, wherein the portion of the foam
profile not coated by the coating layer is disposed proximate the
stiffener.
31. The weatherstrip of claim 26, wherein the foam profile
comprises a hinge shape.
32. The weatherstrip of claim 31, wherein the hinge is covered by a
fabric layer.
33. The weatherstrip of claim 32, wherein the fabric layer is at
least partially covered by the coating layer.
34. A weatherstrip comprising a contiguous exterior surface defined
by a stiffener material, a coating material, and a foam
material.
35. The weatherstrip of claim 34, wherein the stiffener material
comprises a polypropylene.
36. The weatherstrip of claim 35, wherein the stiffener material
comprises at least one barb.
37. The weatherstrip of claim 36, wherein the stiffener material
comprises a substantially L-shaped profile.
38. The weatherstrip of claim 37, wherein the coating material
comprises a resin.
39. The weatherstrip of claim 38, wherein the coating material
comprises a thermoplastic polymer.
40. The weatherstrip of claim 39, wherein the coating material is
non-contiguous about the foam profile.
41. The weatherstrip of claim 39, wherein the thermoplastic polymer
comprises at least one of such as an olefinic plastic/olefinic
rubber blends, a partially or fully cross-linked rubber, a
polyethylene, am ethylene/methacrylic acid copolymer, an
ethylene/ethyl acrylate polymer, a linear low density polyethylene
polymers, a linear low density polyethylene copolymer, an ethylene
interpolymer/chlorinated polyolefin blend, an ionomers, a
polypropylene copolymer, a polypropylene copolymer, a nylon, a
polyester, and a thermoplastic polyurethane.
42. The weatherstrip of claim 40, wherein the foam material
comprises a low-density foamed thermoplastic elastomer.
43. The weatherstrip of claim 42, wherein the foam material
comprises a substantially hinge-shaped profile.
44. A weatherstrip made according to a method comprising: providing
a foam profile; providing a stiffener; attaching the stiffener to
the foam profile; and passing the foam profile and the stiffener
through a resin coating die, wherein the resin coating die
comprises a metering gap between the resin coating die and selected
portions of the foam profile, wherein at least a portion of the
foam profile is uncoated by resin upon exit from the coating
die.
45. The weatherstrip of claim 44, wherein the method further
comprises applying a fabric layer to at least one of the foam
profile and the resin coating.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and incorporates by
reference herein in its entirety U.S. Provisional Patent
Application Ser. No. 60/780,991, filed on Mar. 10, 2006.
TECHNICAL FIELD
[0002] The present invention generally relates to methods, systems,
and apparatus for fabricating a fabric-reinforced (clad) coated
foam substrate, and the products manufactured by the disclosed
methods, systems, and apparatus.
BACKGROUND OF THE INVENTION
[0003] Non-reinforced coated substrates may be manufactured by a
number of methods, as described with reference to FIGS. 1-10 and in
the accompanying text. The methods and systems associated with the
manufacture of non-reinforced coated substrates are also described
in U.S. Pat. No. 5,192,586 to Mertinooke et al., the disclosure of
which and all references of record therein and in the reexamination
proceeding thereof are incorporated by reference herein in their
entireties.
[0004] In many applications, it is desirable to provide a
relatively thin, outer layer or skin for a substrate, which may be
a rigid or non-rigid foam profile or other material. The substrate
may include a plurality of components, some rigid and some
nonrigid. The layer or skin may perform a variety of functions,
such as protecting the substrate from adverse external conditions,
providing the external surface of the substrate or portions thereof
with characteristics suitable for particular applications,
providing an aesthetically appealing finished product, and the
like. The outer layer or skin may also improve the tear resistance
of the substrate and enhance overall strength providing a more
durable and rugged finished product. A conducting wire surrounded
by an insulating layer is one example of a substrate having an
outer layer performing such functions. One such substrate which may
include an outer layer or skin is a weatherseal or weatherstrip,
embodiments of which are described herein, however, the method and
apparatus described herein are not limited in this respect; indeed,
it is broadly applicable where it is desired to provide an outer
layer or skin for rigid and non-rigid substrates including, but not
limited to, foams, metals, and previously extruded plastics.
[0005] In general, weatherseals seal joints or spaces around doors
and windows so as to inhibit infiltration of air, rain, snow, and
other elements. Effective weatherseals can reduce both heating
costs in winter and cooling costs in summer. Certain
characteristics are desirable to produce an effective weatherseal.
First, a weatherseal should have good compression set resistance.
Compression set resistance refers to the ability of a material to
resume its initial shape after being subjected to a compressive
load. Failure to resume this initial shape may result in an uneven
seal and reduce the effectiveness of the weatherseal. Second, a
weatherseal should be soft and yielding, i.e., it should be easily
compressible and conform to irregular surfaces. The gaps in doors,
windows and the like in which weatherseals are utilized differ in
size due to construction and other factors, and a weatherseal
should have sufficient compressibility to conform to a wide range
of gap sizes. Compressibility also ensures that a door or window,
for example, can be closed without excessive force and still
compress the weatherseal sufficiently to form the necessary
seal.
[0006] The prior art discloses many materials which are utilized as
weatherseals. U.S. Pat. Nos. 4,328,273 and 4,185,416 disclose the
use of urethane foams for a weatherseal. Commonly assigned U.S.
Pat. Nos. 4,898,760, 5,192,586, 5,393,796, 5,512,601, 5,607,629,
5,654,346, 5,728,406, and 5,788,889, the disclosures of which are
incorporated herein by reference in their entireties, disclose the
use of a low density foamed thermoplastic elastomer for a
weatherseal. However, these and similar materials may have
relatively high coefficients of friction and may be easily damaged.
Thus, their effectiveness and utility as a weatherseal may be
reduced. These problems are magnified where the weatherseal is
subjected to sliding contact or other abrasive forces; thus, a
method of manufacturing a weatherstrip having reduced frictional
characteristics when sliding against a surface is desirable.
[0007] In order to alleviate the problems described above, an outer
layer or skin is typically provided for the weatherseal. The outer
layer generally has a low coefficient of friction relative to the
surface of contact to facilitate relative motion and may be
generally flexible to permit compression of the underlying seal.
The outer layer also protects the seal from rips and tears caused
by sliding contact or other abrasive forces. Low friction materials
such as polyethylene copolymers, polyvinylchloride, and
polypropylene copolymers have been utilized in the prior art for
this outer layer.
[0008] There are several disadvantages, however, associated with
providing these low friction outer layers. Attaching the outer
layer to the underlying seal may require a separate manufacturing
step and increase the labor and associated costs required to make
the seal. If the outer layer is applied as a crosshead extrusion to
the weatherseal, orientation of the outer layer during "draw-down"
onto the seal creates low resistance to tears along the length of
the seal. Thus, an initially small tear in the outer layer can
propagate into a much larger tear, adversely affecting the
effectiveness and utility of the weatherseal. Additionally,
crosshead extrusion apparatus generally requires complex
arrangements of equipment and expensive dies. These factors also
increase production costs.
[0009] One prior art technique provides an outer skin for a
substrate by melting a resin and placing the melted resin in a tank
or pool with an entrance opening and an exit opening. The substrate
is then pulled or dragged through the melted resin. The exit
opening serves as a doctor blade to configure the outer layer.
However, it is difficult to precisely control the thickness of the
outer layer or to selectively coat portions of the substrate
utilizing this prior art technique. Also, it is difficult to
provide an outer layer of varying thickness. Finally, the pressure
and drag exerted on a non-rigid substrate such as a foam by a
viscous melted resin deforms and stretches the non-rigid substrate
and generates a low quality product.
SUMMARY OF THE INVENTION
[0010] Notwithstanding the benefits of substrates coated in
accordance with the teachings of U.S. Pat. No. 5,192,586, there
exists a need for more robust coated substrates to achieve
heretofore unprecedented performance characteristics. FIGS. 11-19
and accompanying text describe embodiments of the present
invention. The methods described in these figures may be
incorporated into the methods of manufacture described in the
former figures to produce fabric-reinforced coated substrates. The
addition of a fabric layer or other reinforcing layer may be
desirable for additional reinforcement, cushioning, or sealing.
Certain fabrics have been elements of weatherstrip sealing products
since their introduction in the 1980's, forming barriers against
air and water infiltration as part of properly applied window and
door system designs. The fabrics can contribute toward quiet
operation, low friction (low operating forces), low water and air
penetration, puncture resistance, tear resistance, colorability, UV
resistance and long-term weatherability, chemical resistance, and
thermal adhesion to olefin thermoplastic substrates.
[0011] Fabric clad weatherstrip offers many features such as design
versatility, with many skin options utilizing an extruded polymer
thermoplastic vulcanizate (TPV), for similar applications. Other
performance characteristics may also be enhanced by varying the
polymer grade and the layers of polymer added to the skin layers
over the foam in order to solve specific application issues;
however, some prior art solutions become cost prohibitive or
unreliable to consider due to their complexity or raw material
cost. One such challenge is the difficulty created by applying a
weatherstrip in a meeting rail or in a jamb in a tilt double hung
application, where lateral forces are generated on a highly
flexible seal, causing it to tear.
[0012] In one aspect of this invention, the benefits of tear
resistant, low friction polypropylene fabric are combined with the
compression set resistance of TPV foam to provide a product of
superior performance, utilizing an industry-proven TPV sealing
component, while providing a cost effective production method of
applying the fabric to the foam substrate. The fabric can be
utilized to fully or partially encapsulate the foam core, and the
extruded coating tie layer may bond to the inside of the fabric and
to the stiffener for structural integrity and stability. In various
embodiments, the fabric may be applied in strips to provide low
friction areas, hinges, reinforced areas, chafe resistant areas, or
color match areas in order to impart specific characteristics to
the product. The underlying extruded layer of polymer may be simply
a bonding material, requiring no UV protection or low friction
characteristics, that being provided by the exterior layer, or it
may be of lower cost material to simply act as a tie layer. The
fabric may have a secondary extruded layer extruded onto or along
the edges to protect them from catching and lifting with use. The
secondary layer can utilize polyethylene, TPV, thermoplastic
elastomer (TPE), polyester, polypropylene, acrylonitrite butadrene
styrene (ABS), polystyrene ethylene butadiene styrene (SEBS),
ethylene vinyl acetate (EVA), or other suitable and thermally
compatible material.
[0013] The teachings of the invention can be practiced in many
ways. One method is to apply a strip of fabric from a roll of
material directly onto the skin coating, immediately after the skin
has been applied, in a coat die while the skin is still in the
molten state. The fabric may be pre-heated to enhance the bonding
to the skin by the use of directed hot air or a hot plate. The
fabric may travel over a roller downstream of the die opening, the
roller being adjustable to apply appropriate pressure against the
molten skin to achieve a bond. An alternative method is to attach a
die plate to the front of the coat die with a channel cut upstream
of the front plate at a right angle to the product, slightly larger
than the size of the fabric. The fabric follows the channel to the
freshly coated surface and attaches to the coating skin layer
immediately after the coat die plate. The fabric application plate
may utilize a profile cavity configured so as to exert pressure on
only the part of the product where the fabric is being applied, the
rest of the area being relieved, so as not to interfere with the
cooling of the remainder of the molten skin layer.
[0014] In another aspect, the invention relates to a method of
applying a reinforcing material to a coated substrate including a
foam profile, a stiffener, and a resin coating, the method
including the steps of providing a reinforcing material application
station downstream from a resin coating station, a stiffener
application station and a foam profile extruder, and applying the
reinforcing material to the substrate after application of a resin
coating, while the resin has a substantially liquid state. In an
embodiment of the above aspect, the reinforcing material
application station includes a pressure roller.
[0015] In another aspect, the invention relates to a method of
making a weatherstrip, the method including the steps of providing
a foam profile, providing a reinforcing material, and passing at
least a portion of the profile through a coating die to coat the
profile with a resin, wherein the resin attaches the reinforcing
material to the weatherstrip. In certain embodiments of the above
aspect, the coating substantially covers the reinforcing
material.
[0016] In another aspect, the invention relates to a weatherstrip
having: a foam profile, a coating layer disposed along at least a
portion of the foam profile, and a reinforcing material at least
partially in contact with the coating layer. In embodiments of the
above aspect, the reinforcing material is disposed between the foam
profile and the coating layer. In other embodiments, the
reinforcing material is disposed on an outer surface of the coating
layer, and may include a stiffener.
[0017] In another aspect, the invention relates to an apparatus for
manufacturing coated weatherstrip, the apparatus having a foam
extruder, a stiffener roll, a coating die and coating extruder, and
a puller. In certain embodiments of the above aspect, the apparatus
includes a heat source, which may be a hot plate and/or a hot air
discharge to heat the foam after extrusion. In certain embodiments,
the apparatus includes a fabric applicator, which may be located at
or near the outlet of the foam extruder. In certain embodiments,
the applicator may be located at the heat source, or it may be
located where the stiffener is secured to the foam. Alternatively,
the applicator may be located beyond the stiffener application
location. In other embodiments, the fabric applicator may be
integral with the coating die, or may be located between the
coating die and the puller.
[0018] In another aspect, the invention relates to an apparatus for
manufacturing coated weatherstrip, wherein the fabric applicator
for securing the fabric to the extruded foam is a roller, the
roller being used with an opposing roller or a support plate. In
embodiments of the apparatus where a heat source is utilized, the
roller and/or support plate or roller may serve as the heat source.
In certain embodiments of the above aspect, where the fabric is
applied to the extruded foam at the point of application of the
stiffener, the apparatus may include one or more pressure rollers.
In other embodiments, the fabric applicator may be a plate and/or a
fabric applicator die. In embodiments of the above aspect that
utilize a die, the die may be attached to the coating die with or
without a thermal break.
[0019] Accordingly, it is an object of the present invention to
provide a method and apparatus for coating a substrate which is
simple and relatively low in cost. It is another object of the
present invention to provide a method and apparatus for coating a
substrate which produces a less oriented outer layer. It is still
another object of the present invention to provide a method and
apparatus for producing a substrate having a multiple-component
outer layer. It is still another object of the present invention to
provide a method and apparatus for providing a substrate with an
outer layer of varying thickness which may be selectively applied
to portions of the substrate. It is still another object of the
present invention to overcome the disadvantages of the prior
art.
[0020] In another aspect, the invention relates to a method of
making a weatherstrip having a foam profile, a resin coating, and a
cover layer, the method including the steps of providing the foam
profile, providing the cover layer, and passing the cover layer and
the foam profile through a resin coating station, wherein at least
a portion of the cover layer is coated with the resin, while the
resin is in a substantially liquid state. In embodiments of the
above aspect, the method also includes the step of applying the
cover layer to at least a portion of the foam profile. Other
embodiments include the step of attaching a stiffener to at least
one of the foam profile and the cover layer. In certain of those
embodiments, the passing step further includes passing the
stiffener through the resin coating station, which may coat at
least a portion of the stiffener with resin. In other embodiments
of the above aspect, the cover layer includes an edge, at last a
portion of which is coated with the resin. In still other
embodiments, the cover layer includes a coated side and a reverse
side, and the reverse cover layer side is disposed proximate to the
foam profile. In certain of those embodiments, the coated cover
layer side and the resin form a bond upon contact. Additional
embodiments of the above aspect adhere at least a portion of the
cover layer to at least a portion of the foam profile. Still other
embodiments include the steps of providing a forming station
upstream from the resin coating station, and passing the cover
layer through the forming station to preform the cover layer to a
shape corresponding to a shape of the foam profile.
[0021] In yet another aspect, the invention relates to a method of
making a weatherstrip having a foam profile, a resin coating, and a
cover layer, the method including the steps of providing a foam
profile, passing the foam profile through a resin coating station,
wherein at least a portion of the foam profile is coated with the
resin, while the resin is in a substantially liquid state, and
applying the cover layer to at least a portion of the foam profile.
In certain embodiments of this aspect, the portion of the foam
profile to which the cover layer is applied is coated with the
resin. Additional embodiments of the above method include the step
of attaching a stiffener to at least one of the foam profile and
the cover layer, and may include passing the stiffener through the
resin coating station, which may coat at least a portion of the
stiffener with resin. Certain embodiments of the above aspect
include the step of applying the cover layer to the foam profile
prior to the passing step. In other embodiments the cover layer is
applied to the foam profile with at least one roller, which may
occur while the resin is in a substantially liquid state. Certain
embodiments of any of the above aspects may include a cover layer,
wherein the cover layer forms at least one wand, and/or the cover
layer may be abraded.
[0022] In other aspects, the invention relates to a weatherstrip
made in accordance with any of the above-recited methods. In
another aspect, the invention relates to a weatherstrip having a
foam profile, a stiffener, and a cover layer over the foam profile
attached to at least one of the foam profile and the stiffener
along longitudinal edges of the cover layer, so as to decouple at
least a portion of the cover layer from the foam profile. In
another aspect, the invention relates to a system for manufacturing
weatherstrip, the system having a foam profile source, a stiffener
source, a cover layer source, a resin source, a device for
attaching the stiffener to the foam profile, a device for at least
one of applying the cover layer to at least a portion of the resin
and applying the resin to at least a portion of the cover layer,
and a device for coating with resin at least a portion of at least
one of the foam profile and the stiffener. In still another aspect,
the invention relates to a method of making a weatherstrip having a
cover layer and at least one of a foam profile and a stiffener, the
method including the steps of providing the cover layer, providing
at least one of the foam profile and the stiffener, applying at
least a portion of the cover layer to the at least one of the foam
profile and the stiffener to create a combined component, and
passing the combined component through an ultrasonic welding
station, thereby securing at least a portion of the cover layer to
the at least one of the foam profile and the stiffener.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A more complete appreciation of the invention in accordance
with the depicted embodiments and many of the attendant advantages
thereof will be readily obtained by reference to the following
detailed description when considered in connection with the
accompanying drawings, in which:
[0024] FIG. 1 is a block diagram illustrating the overall operation
of one embodiment of an apparatus for manufacturing coated
weatherstrip;
[0025] FIG. 2 is a plan view of a die plate in accordance with one
embodiment the coated weatherstrip manufacturing apparatus of FIG.
1;
[0026] FIG. 3 is a cross-sectional view illustrating the coating of
a substrate using the die plate of FIG. 2;
[0027] FIG. 4 illustrates a weatherseal formed in accordance with
one embodiment of the coated weatherstrip manufacturing apparatus
of FIG. 1;
[0028] FIG. 5 is a plan view of a die plate in accordance with
another embodiment of the coated weatherstrip manufacturing
apparatus of FIG. 1;
[0029] FIG. 6 illustrates a glass run channel formed with the die
plate of FIG. 5;
[0030] FIG. 7 is a partial block diagram illustrating the operation
of another embodiment of a coated weatherstrip manufacturing
apparatus;
[0031] FIG. 8 illustrates a weatherseal formed in accordance with
the embodiment of the coated weatherstrip manufacturing apparatus
of FIG. 7;
[0032] FIG. 9 illustrates another weatherseal formed in accordance
with another embodiment of the coated weatherstrip manufacturing
process;
[0033] FIG. 10 is a plan view of a die plate in accordance with
another embodiment of the coated weatherstrip manufacturing
apparatus to produce the weatherseal of FIG. 9;
[0034] FIG. 11 is a schematic representation of a manufacturing
apparatus in accordance with one embodiment of present
invention;
[0035] FIG. 12 is a schematic representation of a manufacturing
apparatus in accordance with another embodiment of the present
invention;
[0036] FIGS. 13A-13F are block diagrams of various embodiments of
fabric application processes suitable for use in the manufacturing
apparatus depicted in FIG. 12;
[0037] FIG. 14 is a schematic end view of one embodiment of the
fabric applicator die of FIG. 13E;
[0038] FIGS. 15A-15C are schematic side views of fabric applicators
in accordance with other embodiments of the present invention;
[0039] FIGS. 16A-16L are schematic sectional views of various
embodiments of fabric-clad foam weatherstrips in accordance with
certain embodiments of the present invention;
[0040] FIG. 17 is a schematic sectional view of a fabric-clad
extruded hollow bulb seal in accordance with an embodiment of the
present invention;
[0041] FIGS. 18A-18D are schematic sectional views of a fabric-clad
weatherstrip manufactured in accordance with alternative
embodiments of the present invention; and
[0042] FIG. 19 is a schematic sectional view of an embodiment of a
fabric-clad foam weatherstrip manufactured utilizing ultrasonic
welding.
DETAILED DESCRIPTION
[0043] FIG. 1 schematically illustrates the overall operation of
one embodiment of an apparatus for manufacturing coated
weatherstrip. The product produced in this process is a weatherseal
of the type shown in FIG. 4, which includes a foam body or profile
with a thin skin or coating and having bonded thereto a stiffener
which is used to attach the weatherseal to a structure, such as a
door or window jamb. The stiffener is supplied from a reel 20. The
stiffener is first heated to approximately 120.degree.-240.degree.
F. by a hot air blower, for example, in order to slightly soften
the stiffener and to facilitate the removal of twists or bends in
the stiffener as it is uncoiled and subjected to longitudinal
tension. The heating also increases the temperature of the
stiffener which permits a more secure bond to be formed with the
adhesive and skin material in processing steps described below.
[0044] The stiffener is then subjected to a corona treatment or
other surface treatment method to enhance bonding of the adhesive
to the stiffener and the skin to the stiffener. Next, an adhesive
is applied to the stiffener. The adhesive may be applied by a
conventional hot melt system or other methods. The adhesive may be
chosen to effect secure bonding of the foam to the stiffener. It
will be recognized by those skilled in the art that the adhesive
utilized will depend on the materials to be bonded as well as the
temperatures the resultant structure will experience during
subsequent processing steps and in use as a weatherseal. In one
embodiment, effective bonding of low density SANTOPRENE.RTM. foam
to a polypropylene stiffener is achieved with hot melts such as
EXTREME ADHESIVES.RTM. ADT-067 or other amorphous polypropylene
based hot melts, or thermoplastic rubber-based pressure sensitive
hot melts. SANTOPRENE is manufactured by Advanced Elastomer
Systems, LP. EXTREME ADHESIVES ADT-067 is manufactured by Adhesive
Engineering & Supply, Inc. The characteristics and properties
of SANTOPRENE are disclosed in U.S. Pat. Nos. 4,130,535 and
4,311,628, the disclosures of which are incorporated by reference
herein in their entireties. SANTOPRENE is a thermoplastic
elastomeric composition including blends of olefin rubber and
thermoplastic olefin resin.
[0045] Foam is supplied from a reel 30. The foam is preferably a
low density thermoplastic elastomeric foam described in the
aforementioned patents. The foam is bonded to the stiffener to
which the adhesive has been applied at a point schematically
indicated at 35. In order to secure an effective bond, the foam may
advantageously have no longitudinal tension as it is bonded to the
stiffener.
[0046] The foam-stiffener combination is then pulled through a
coating die, such as die 40, where an outer layer or skin of a
melted resin produced by an extruder 42 is applied. The details of
the application of this outer layer or skin are discussed below.
After being pulled through the die 40, the resultant weatherseal is
cooled by a spray mist of water, a water bath, or forced air. An
air wipe subsequently removes excess water from the weatherseal, if
necessary. The coated weatherseal passes through a puller 46 prior
to storage or packaging. The puller 46 generates the necessary
force for pulling the foam-stiffener combination throughout the
above-described operation. Generally, the puller may produce a line
speed in ranges from about 10 to 200 feet per minute to about 50 to
100 feet per minute. In certain embodiments, the line speed for
producing the weatherstrip is about 60-75 feet per minute; in other
embodiments, the line speed is about 75-100 feet per minute.
Factors such as the surface area of the substrate or portions
thereof which are to be coated effect the line speed and may be
taken into consideration.
[0047] It is not necessary that the foam and stiffener be unwound
from reels. It is possible, for example, for either the foam or
stiffener or both to be extruded in line with the apparatus of the
present invention. Such an arrangement requires proper control of
the various line speeds but results in a single production line for
the product.
[0048] With reference to FIG. 2, a die plate 50 of the die 40 is
typically formed of metal and has a thickness ranging from about
0.5 to 0.75 inches. These dimensions, however, will vary with the
requirements of the particular coating process. The die plate 50
includes a resin channel 55 formed on one side thereof. The resin
channel 55 has a depth of approximately 0.25 inches. As noted with
respect to die thickness, this dimension is not critical and may be
varied in accordance with the requirements of a particular coating
process. An opening 60 is coupled to the output of an extruder 42
shown in FIG. 1. The opening 60 admits resin melted by the extruder
42 into the resin channel 55. Although the resin admitted to the
resin channel 55 in the present embodiment is produced by an
extrusion apparatus, this is not a necessary requirement. For some
materials, the application of sufficient heat will create a melt
which may be forced into the die under pressure by conventional
pumping techniques. The pressure is approximately 100 pounds per
square inch (psi) and may vary between about 50 and 1000 psi
depending on the coating process. Some polymers, however, may
require both heat and shearing action to produce a melt and
therefore require an extrusion apparatus. Still other resins for
coating a substrate, such as latex type resins, are room
temperature liquids and hence do not require melting and may simply
be forced into resin channel 55 under pressure.
[0049] The melted resin admitted to the resin channel 55 via the
opening 60 is divided into two streams by a die portion 65. The
resin within the resin channel 55 is at a pressure determined by
the operating conditions of the extruder 42 (e.g., temperature,
screw speed, temperature profile, etc.), the die configuration and
the metering gap (described below). Increasing the screw speed of
the extruder 42, for example, increases the pressure within the
resin channel 55. As discussed below, the pressure within the resin
channel 55 controls the thickness of the coating layer or skin
deposited on the substrate.
[0050] A die opening 70 is formed with a wall portion 75 having
varying heights or thicknesses. The illustrated die opening is
configured to produce the door or window seal of FIG. 4. It will be
recognized that the die opening 70 may be configured to coat
substrates of any shape in accordance with the discussion below. As
detailed below, the height of the wall portion 75 varies in
accordance with the position of the wall portion in the resin
channel 55 and the thickness of the outer layer or skin desired on
the substrate at that point. The die plate 50 cooperates with a
face or scraper plate 90 having an opening 91 therein corresponding
to the die opening 70 and which is secured thereto in a manner to
enclose the resin channel 55 as shown in FIG. 3. The gaps between
the face plate 90 and the wall portion 75 form a metering gap 92
for the resin.
[0051] The pressure within the resin channel 55 is a function of
position therein and generally decreases with increasing distance
from the opening 60 so as to generate a range of pressures within
the channel 55. Therefore, in order to provide a layer of uniform
thickness to a substrate, the height (or thickness) of the wall
portion 75 may be varied such that the size (or length) of the
metering gap 92 is correlated with the pressure at that point to
generate a uniform resin flow onto all portions of the substrate.
For example, the height of the wall portion at point 80 should be
greater than the height of the wall portion at point 85 since the
pressure on the resin at point 80 is greater than the pressure on
the resin at point 85. The decreased wall portion height at point
85 forms a larger metering gap and permits a greater volume of
melted resin to flow between the face plate 90 and the wall portion
to compensate for the reduced pressure and the flow characteristics
of the material being applied. Additionally, the thickness of the
wall may be varied by adjusting the length of the land on the top
of the wall portion, as required for particular applications.
[0052] The size of the height of metering gap 92 varies between
about 0.00 to 0.2 inches in one embodiment for the door seal. The
size of the metering gap may vary depending on the requirements of
particular coating operation. The size of the metering gap at
various portions of the resin channel may be varied to provide a
uniformly thick skin or to provide a skin whose thickness varies
depending on position. The ability to provide a skin of varying
thickness is an advantage over techniques of pulling a substrate
through a pool of melted resin. In such techniques, the thickness
of the skin is not easily controlled and may cause different
portions of the substrate to be coated with different
thicknesses.
[0053] An optional ridge 87 illustrated in FIG. 3, is formed on an
inner side of the wall portion 75. The ridge 87 is spaced
approximately 0.050 inch below the top of the adjacent wall portion
and is approximately 0.030 inch wide in one embodiment. The 0.050
inch spacing is not critical and the ridge 87 is not necessary.
Generally, if included, the spacing should be sufficient to provide
a pocket 97 of reduced pressures as compared with the first range
of pressures within resin channel 55. The pocket 97 is thus
maintained within a second pressure range, the pressures in the
second pressure range being lower than pressures in the range of
pressures in resin channel 55. The pressures in the second pressure
range are generally about atmospheric pressure. The ridge 87
further forms a shoulder which can prevent some of the wall portion
75 from contacting a substrate 101 as it is pulled through the die.
It has been determined that if an excessive length of wall portion
75 contacts the substrate 101, a uniform skin may not obtained and
a product of low quality may be produced in certain instances. In
some instances, the ridge 87 permits the resin from the resin
channel 55 to flow through the metering gap 92 into the pocket 97
at a lower pressure from where it subsequently flows onto the
substrate 101 being pulled through the die opening 70. Thus, a low
pressure thin stream of resin flows into the pocket 97. Although
the resin is at high pressure in resin channel 55, the ridge 87 may
form a low pressure region or a pocket 97 for applying the resin to
the substrate 101. The application of the resin at approximately
atmospheric pressure aids in the production of a uniform skin.
Testing has demonstrated, however, that neither the ridge 87 or the
pocket 97 are required to produce a high quality uniform
coating.
[0054] The face plate 90 is secured to the die plate 50 by screws
for example (not shown). The substrate 101 enters the die through a
tapered lead 95. The tapered lead 95 ends in a contact surface or
shoulder 99. The shoulder 99 and the surface 98 serve to position
the substrate 101 in the die opening and further prevent the resin
from traveling back away from face or scraper plate 90. The resin
coated on to the substrate is doctored by the face plate 90 made of
metal with the door seal profile cut therein to produce an outer
layer 102. Thus, a low pressure, thin stream of resin is forced
into the pocket 97 from all sides and as it contacts the substrate,
it is doctored.
[0055] The thickness of the skin applied to a substrate generally
depends on the line speed, the volumetric flow rate of the resin,
and the doctoring by the face plate. However, assuming a constant
line speed, the coating of rigid and non-rigid substrates seems to
have slightly different mechanisms. The thickness of the skin on a
non-rigid substrate such as foam appears to be determined by the
metering gap and the pressure in the resin channel. As more
material is forced through the metering gap, the non-rigid
substrate is deflected or compressed more and a thicker skin is
produced. If not as much material is forced through the metering
gap, the non-rigid substrate is deflected or compressed less and a
thinner skin is produced. The face plate does not appear to play a
critical role in determining the skin thickness for non-rigid
substrates or non-rigid portions of substrates. However, there is
much less deflection with a rigid substrate and the face plate
plays a more important role in determining thickness by scraping or
doctoring the applied resin. In the die configuration of the
above-described embodiment, the rigid portion of the door seal
passes through the die opening at a point remote from opening 60,
and consequently, the resin is at a relatively low pressure. It is
important to ensure that sufficient material is supplied to provide
a skin for the rigid portion. A flow channel may be cut into the
face plate to increase the resin flow at that point. In various
embodiments, some or all of the resin channel may be formed in the
face plate.
[0056] Utilizing certain embodiments, it is also possible to coat
only selected portions of a substrate by providing no metering gap
at particular points in resin channel 55. That is, at particular
points, the top of wall portion 75 abuts face plate 90 and no resin
flows though. This may be desirable in applications such as
weatherseals where portions of the seal perform functions adversely
affected by the application of a skin. The door seal of FIG. 4
depicts such a situation. A door seal 100 includes a foam profile
105 and a stiffener or attachment device 110. An adhesive layer 112
bonds the foam profile 105 to the stiffener 110. The stiffener 110
includes barbs 115, which secure the door seal 100 in a jamb or the
like. As noted above, the skin 107 should have a low coefficient of
friction in order to facilitate the opening and closing of a door.
However, this low friction skin 107 should not cover the barbs 115,
so that the seal can be effectively secured to the door jamb. A low
friction layer covering the barbs 115 would inhibit their ability
to maintain a secure attachment. Such selective application of a
skin can not be obtained by pulling or dragging the door seal
through a pool of melted resin.
[0057] In certain embodiments, the applied resin may also be
sufficiently hot to form a thermal bond with those portions of the
substrate to be coated. In one embodiment, the SANTOPRENE foam and
the polypropylene stiffener are coated with a non-foamed
SANTOPRENE-blend skin. The SANTOPRENE blend preferably consists of
750 parts of SANTOPRENE 221-64, 250 parts of SANTOPRENE 223-50, 50
parts Ampacet #10061 (a slip additive), and 80 parts of a color
concentrate. The numerical designation following "SANTOPRENE" is a
commercial product code which defines certain characteristics of
the SANTOPRENE grade. The SANTOPRENE blend is extruded from a
single screw extruder. The temperature of the melted SANTOPRENE
blend should be approximately 480.degree. F. to form a thermal bond
with the stiffener and the foam. The SANTOPRENE-blend skin has a
relatively low coefficient of friction, is soft and compliant, has
good strength and has a good resistance to compression set. The
SANTOPRENE-blend skin also achieves a good thermal bond with the
SANTOPRENE foam and the polypropylene stiffener.
[0058] The above-described method may be utilized with resins
having a wide range of viscosities. Suitable skin materials for
appropriate rigid and non-rigid substrates (or combinations of the
two) include thermoplastic polymers such as olefinic
plastic/olefinic rubber blends, partially or fully cross-linked
rubber versions of the above including SANTOPRENE, polyethylene,
ethylene/methacrylic acid copolymer, ethylene/ethyl acrylate
polymer, linear low density polyethylene polymers and
copolymerizations therewith, ethylene interpolymer/chlorinated
polyolefin blends, ionomers (SURLYN.RTM.), polypropylene and
polypropylene copolymers, nylon, polyesters, and thermoplastic
polyurethane and mixtures thereof. SURLYN is a registered trademark
of DuPont. As noted above, room temperature liquid resins such as
latex emulsions compounded from silicones, acrylics, polyurethanes,
and natural or synthetic rubbers may also be used.
[0059] A die plate utilized to manufacture coated weatherstrip and
the resulting weatherstrip is illustrated in FIGS. 5 and 6. FIG. 5
illustrates a die plate generally indicated at 140. The die plate
140 includes a resin channel 155 formed on one side thereof and an
opening 160. A die opening 170 is formed with wall portions 175
having varying heights and having a ridge 187 formed on the inner
surface thereof. The die portion illustrated in FIG. 5 is
configured so as to produce the glass run channel 201 of FIG. 6.
The glass run channel 201 includes a roll-formed metal channel 205
having semi-cylindrical foam portions 210a, 210b, 210c adhesively
secured to inner walls 207, 208, 209 respectively.
[0060] In order to coat the surfaces of foam portions 210a, 210b,
210c with an outer layer 220, the glass run channel 201 is pulled
through the channel of die opening 170. Resin is forced by pressure
in resin channel 155 through metering gaps formed by wall portions
175 and a corresponding face plate (not shown) in a manner similar
to that discussed with respect to the above described
embodiment.
[0061] The methods and apparatus described herein may also be
utilized to provide multiple outer layers to a substrate. Thus,
with reference to FIG. 7, a substrate such as the foam-stiffener
combination described above may be pulled through a die 340 having
a liquid resin supply 345 and be coated with a first outer layer.
If it were desired, for example, to provide strips of a lower
friction material over the first outer layer in order to produce a
low friction contact surface, the foam-stiffener combination with
the first outer layer could be pulled through a second die 350
having a liquid resin supply 355. This would generate the low
friction strip 345 on a weatherseal 310 as illustrated in FIG. 8.
For example, the first die may apply a skin utilizing the
above-referenced the SANTOPRENE blend while the second die may
apply a latex skin as a low friction overcoat. The heat from
SANTOPRENE cures or dries the latex. Alternatively, the second die
may pump a slurry of water and micronized polyethylene or
tetrafluorethylane powder or silicone powder or other low friction
material onto the hot SANTOPRENE. It will be apparent that this
second layer may cover all or any portion of the first layer in
accordance with the desired final product. It will also be apparent
that any number of layers may be provided. Embodiments of a product
utilizing a low friction layer, and systems and methods of
manufacturing same, are described in more detail below.
[0062] Still another embodiment of the method of manufacturing
coated weatherstrip may utilize the multiple die arrangement of
FIG. 7. A substrate such as the foam-stiffener combination
described above may be pulled through the die 340 and be coated
with a first outer layer covering only a selected portion thereof.
The resultant combination could then be pulled through the die 350
and portions of the substrate not covered by the first layer could
be coated with a second layer coextensive with the first layer.
Thus, as shown in FIG. 9, a low friction strip 395 may be provided
directly on a selected portion of the substrate with the remainder
of the coated portions of the substrate covered with a layer 385 of
different material.
[0063] FIG. 10 illustrates a die plate in accordance with another
embodiment of the apparatus for manufacturing coated weatherstrip.
A die plate 440 may be utilized to provide a dual extruded skin.
The die plate 440 includes resin channels 455a and 455b containing
first and second different resins, respectively, for coating a
substrate pulled through a die opening 470. The first resin is
admitted to the resin channel 455a through an opening 460a and the
second resin is admitted to the resin channel 455b through an
opening 460b. The resin in the resin channel 455a is divided into
two streams by a die portion 465. The resin channels 455a and 455b
are formed such that there is no mixture of the first and second
resins in the channels. The first and second resins are metered
between a wall portion 475 and a face plate (not shown) into a low
pressure pocket formed by a ridge 487 from where they are applied
to the substrate. The embodiment of FIG. 10 may be used to produce
the weatherseal shown in FIG. 9.
[0064] One aspect of the weatherstrip produced in accordance with
the described methods is that a less oriented skin is produced,
i.e., the skin molecules are not aligned to the same degree as they
would be in a crosshead extrusion. The low orientation produces a
skin which is strong and rubbery. The skin has uniform strength in
all directions and does not propagate lengthwise tears. The skin is
less oriented since it is not drawn-down onto the substrate as in a
typical crosshead die as in other prior art methods and
systems.
[0065] In addition, a high pressure die, because of the high
pressures and the resulting flow rates, requires very careful
channeling to ensure that the pressures are balanced. The intricate
channeling and the requirement of withstanding high pressures
require machining and generally increase production costs. The die
used in one embodiment of the described system is utilized in a
relatively low pressure system which tends to balance its own
pressures and does not require intricate channeling. Low pressure
regions in the die of the disclosed apparatus may be easily
compensated for by reducing the height or thickness of the wall
portions. Dies of this type are easier to make and are
significantly less expensive than conventional crosshead dies.
[0066] In one example of manufacturing coated weatherstrip,
SANTOPRENE having a durometer reading of 64 was foamed in
accordance with the method detailed in the aforementioned commonly
assigned patents. A stiffener of polypropylene was bonded to the
foam profile as shown in FIG. 1. A blend of 750 parts SANTOPRENE
221-64, 250 parts SANTOPRENE 223-50, 50 parts Ampacet, #10061, and
80 parts of a color additive was melted in a 11/4'' extruder
operated at 95 revolutions per minute and fed into a die of the
type shown in FIGS. 2 and 3 with the die at 480.degree. F. The
foam-stiffener combination was pulled through the die at 50 feet
per minute and subsequently cooled.
[0067] In accordance with one embodiment of the present invention,
tear-resistant, low-friction, polypropylene fabric or other cover
layer may be combined with the compression set resistance of foam
and a coating layer or skin to provide a product exhibiting
desirable sealing and long life using a cost effective production
method of applying the fabric to the foam substrate. Alternatively,
a porous fabric, non-woven fabric with or without a film layer,
single layer or laminated film, metal mesh, fabric or metal
cladding, reinforcing film or fabric, or woven fabric may be
utilized as the cover layer. The cover layer may be the
fabric/thermoplastic copolymer sold by Xamax Industries, Inc.,
under the trade name FLOLAM.RTM.. Cover layers utilizing a
non-woven polypropylene fabric with a polypropylene film or coating
applied to one or both sides of the fabric may also be utilized.
Such a non-woven polypropylene composite is sold by Xamax
Industries, Inc., under the designation Q ECM. Thickness of the
fabric cover layer may vary from about less than 1 mil to greater
than 5 mil or more, depending on the particular manufacturing
process used, application, etc. Additionally, the fabric layer may
vary from about 1 oz/sq yd to about 2 oz/sq yd or more, depending
on the application. In certain embodiments, the fabric cover layer
is coated with a 2 mil polypropylene film, and has a basis weight
of 1.25 oz/sq yd. The application of the fabric or cover layer may
be incorporated into the systems and methods described above
regarding manufacture of coated foam weatherstrip. Additionally,
the terms "fabric layer," "cover layer," "fabric cover layer,"
"cladding," "sheathing," "fabric laminate," etc., are used
interchangeably herein and throughout this document, and use of one
term or another does not in any way limit the particular type of
layer or material that may be utilized in a particular application.
In certain embodiments, the coating acts as a tie layer, to
permanently bond the fabric layer through combined application of
heat and pressure. The fabric layer can be utilized to fully or
partially encapsulate the foam core. The fabric may be applied in
strips to provide low friction areas, hinges, reinforced areas,
chafe resistant areas, or color match areas in order to impart
specific characteristics to the product. The fabric layer may also
be applied directly to or used in conjunction with substrates other
than foam, such as rigid plastic profiles, hollow extruded bulbs,
etc. The underlying extruded coating layer of polymer or other
material may be used primarily as a bonding material, requiring
little or no UV protection or low friction characteristics. Those
performance features in the product can be provided by the fabric
layer. The coating layer may be a lower cost material to act
primarily as a tie layer, depending on the application and product
exposure to the environment. The fabric layer may optionally have a
secondary extruded layer, extruded onto the edges to protect them
from catching and lifting with use, utilizing polyethylene, TPV,
TPE, polypropylene, ABS, SEBS, or other suitable and thermally
compatible material. Secondary coatings may be extruded onto the
surface of the fabric in order to impart further features, such as
UV resistance, moisture resistance/water tightness, ultra-low
friction coefficients, etc. Additionally, the fabric layer may be
coated with a film or adhesive to improve bonding properties with
the coating. Alternatively, the fabric layer can be attached to the
foam or other portion of the substrate solely by the secondary
layer at solely the edges, or partially or fully along the
cross-sectional extent. Exemplary embodiments of weatherstrip
manufactured in accordance with the present invention are depicted
in FIGS. 16A-16L, though other configurations are clearly
contemplated and within the scope of the invention.
[0068] Various embodiments of the invention are contemplated. One
embodiment of a process line 750 for manufacturing fabric clad
weatherstrip is depicted in FIG. 11. This figure is described in
more detail below. FIG. 12 depicts a clad weatherstrip
manufacturing apparatus 500; letters at various points along the
process line 502 indicate points where the fabric strip may be
applied to the foam profile (A, B), foam profile/stiffener
combination (C, D, E), or coated foam profile/stiffener combination
(F). The process line 502 is similar to that of FIG. 1 and
generally includes a reel of foam profile or a foam profile
extruder 504, a reel 506 of stiffener or a stiffener extruder, and
an optional heat generating device 508 (e.g., a hot air blower 508a
or hot plate 508b). The foam profile 510 and stiffener 512 are
bonded or adhered together and drawn through a coating die 514 by a
puller 516. The coating die 514 may be supplied with molten resin
by a separate extruder 518. The coated foam
profile/fabric/stiffener combination 520 is then rolled or
otherwise processed for storage, distribution, etc. Application of
the fabric strip at the various points are described with reference
to FIGS. 13A-13F.
[0069] FIG. 13A depicts an embodiment of an apparatus 530 that
secures the fabric 532 to the foam profile 510 a distance
downstream of the extruder 504 after the profile 510 has expanded
to substantially its final shape. The fabric 532 is applied to the
profile 510 from a fabric roll 534 utilizing a contoured pressure
roller 536 in combination with a contoured pressure plate 538 or
other roller of the appropriate geometry. The heat generated by the
newly extruded foam profile 510 may aid in adhering the fabric 532
to the profile 510. Downstream of the pressure roller 536, a
stiffener (not shown) is applied to the fabric/foam combination
542.
[0070] FIG. 13B depicts another embodiment of an apparatus 550 that
secures the fabric 532 to the foam profile 510 during a
supplemental heat stage. An optional heat plate 508b, hot air
blower 508a, corona, or other thermal apparatus may be used to heat
the extruded or unreeled foam profile 510 to provide better
adhesion of the fabric 532. Similar to the embodiment depicted in
FIG. 13A, a contoured pressure roller 552 is used in combination
with a support plate 554 or roller of the appropriate geometry to
adhere the fabric 532 to the profile 510. Alternatively, the hot
plate 508b may be used in place of the support plate 554 or roller.
Downstream of the pressure roller 552, a stiffener (not shown) is
applied to the fabric/foam combination 542.
[0071] FIG. 13C depicts an embodiment of a fabric application
apparatus 560 wherein the fabric 532 and stiffener 512 are applied
to the foam profile 510 substantially simultaneously on the process
line. Two opposing contoured pressure rollers 562a, 562b may be
utilized to apply the two components to the profile 510. This
application method may be utilized for profiles 510 that have a
stiffener 512 secured on a side directly or generally opposite the
fabric 532. The resulting foam profile/fabric/stiffener combination
564 can then be passed through the coating die.
[0072] FIG. 13D depicts an embodiment of a fabric application
apparatus 570, wherein the fabric 532 is applied to the foam
profile downstream from the stiffener application. Similar to the
embodiment depicted in FIG. 13A, a contoured pressure roller 572 is
used in combination with a support plate 574 or roller of the
appropriate geometry to adhere the fabric 532 to the
profile/stiffener combination 576. The resulting foam
profile/fabric/stiffener combination 564 can then be passed through
the coating die.
[0073] FIG. 13E depicts another embodiment of a fabric application
apparatus 580, wherein a fabric applicator die or plate 582 is
utilized upstream of the coating die 514 to apply the fabric 532 to
the foam profile/stiffener combination 584. The fabric applicator
plate 582 may be secured or bolted 594 to the coating die 514 with
or without a thermal break 586, which may be air, non-heat
conductive material, or otherwise. A shaped opening 588 in the
plate 582 allows the fabric 532 to be formed properly to secure the
fabric 532 to the foam/stiffener combination 584. Optionally, a
guide 590 may be used to ensure proper forming of the fabric 532
around the foam/stiffener combination 584. After passing through
the fabric applicator plate 582, the fabric/foam/stiffener
combination 590 passes through the coating die 514, where the
exterior layer or skin is applied via the resin channel 592, as
described with regard to the manufacture of coated weatherstrip.
The coated foam profile/fabric/stiffener combination 520 is then
rolled or otherwise processed for storage, distribution, etc. Other
embodiments of fixtures or guides that may be used in place of the
fabric applicator plate 582 are described herein.
[0074] FIG. 13F depicts another embodiment of a fabric application
apparatus 600 wherein the fabric 532 is applied to the coated foam
profile 602 downstream from the coating die 514. Similar to the
embodiments depicted in FIGS. 13A, 13B, and 13D, a contoured
pressure roller 604, is used in combination with a support plate
606 or roller of the appropriate geometry to adhere the fabric 532
to the coated profile 602. In this embodiment, the fabric 532
contacts the freshly coated surface and attaches to the coating
layer immediately downstream of the coating die 514, while the
coating is still in the molten state. The coated foam
profile/fabric/stiffener combination 520 is then rolled or
otherwise processed for storage, distribution, etc.
[0075] FIG. 14 is an end view of one embodiment of the fabric
application plate 582 depicted in FIG. 13E. The plate body 610
defines a tapered, generally conical channel 588; however,
different shapes are contemplated, depending on the geometry of the
profile 510 and desired finished weatherstrip product requirements.
Additionally, a recess 614 may be formed in a lower portion of the
plate 582 to accommodate all or a portion of the stiffener 512. In
the depicted embodiment, a bottom opening 616 of the die 582
retains the foam/stiffener combination 612 as the channel 588
tapers from an oversized profile 588a to a point 588b where the
channel 588 is approximately the same size as the foam/stiffener
combination 612. As the fabric 532 follows the taper of the channel
588, it is gradually formed until it achieves the desired shape and
proximity to the profile 510, at which time it may be adhered to
the foam profile 510. The channel 588 is sized to accommodate both
the fabric 532 and the foam profile 510, with sufficient, gradual
curvature to properly form the fabric 532 so it may be conformed to
the foam profile 510 without undesired creasing. At the point 588b
where the fabric 532 meets the foam/stiffener combination 612, the
channel 588 is sized and configured approximately the same as the
die opening in the resin channel 592 through which the
foam/stiffener/fabric combination 590 passes in the coat die 514
downstream. As the fabric 532 contacts the foam profile 510, it
presses against the profile 510 as it is passed through the coating
die 514.
[0076] Additional fixtures and/or guides may be utilized either
upstream or downstream of the coating die 514 to guide or direct
the fabric layer into the desired position, orientation, and/or
contour on the foam profile. For example, FIGS. 15A-15C show
several embodiments of fabric application stations 620a, 620b, 620c
for applying a fabric 532 to a profile 510 at the entrance of a
coating die 514. Additionally, these fabric guides may be used for
applying a fabric to a profile downstream of the coating die 582.
The fabric guide 622a, 622b, 622c may be secured to the coating die
582, with or without a thermal break, or to any other proximate
structure. Additionally, tapered or funnel-shaped guides are
contemplated to gradually form the fabric to the shape required for
the particular application. The guide can be mounted to the coating
die in the proper orientation and can include a channel or recess
to receive the fabric and orient the fabric to apply it at the
proper location on the profile.
[0077] In the depicted embodiments, the fabric application stations
620a, 620b, 620c include a fabric guide 622a, 622b, 622c that may
be attached directly to the coating die 582. Alternatively, the
fabric guide 622a, 622b, 622c may be independent of the coating die
582. In FIG. 15A, one embodiment of the fabric guide 622a is
depicted that includes a rod 624a or bar that spans a pair of
armatures 626a forming an opening through which the fabric 532 can
pass. The fabric 532 is routed between the armatures 626a and
guided by the bar 624a, which may be grooved or shaped to contour
the fabric 532 to a desired configuration. Another fabric guide
622b is depicted in FIG. 15B. In this embodiment, a guide plate
624b is utilized to conform the fabric 532 to a desired shape prior
to passing the fabric 532 and foam/stiffener combination 576
through the coating die 582. The plate 624b may have an opening
similar to that depicted in FIG. 14. Alternatively, the opening may
utilize a different taper or radius of curvature to shape the
fabric, as required.
[0078] FIG. 15C depicts a fabric guide 622c having multiple rods or
bars 624c that allow the approach angle .alpha. of the fabric to
the foam/stiffener combination 576 to be adjusted, as required for
a particular application. Additionally, the fabric roll (not shown)
may be positioned such that an initial approach angle of the fabric
532 relative to the foam/stiffener combination 576 (i.e., the
fabric angle .theta.) may be adjusted as needed to provide
sufficient clearance depending on the application, fabric
qualities, etc. Approach angles .alpha. between greater than
0.degree. and less than about 90.degree. are contemplated. For foam
profiles having a generally flat top surface, the approach angle
.alpha. may be larger than those used for contoured profiles. In
one embodiment for a round profile, the approach angle .alpha. and
the fabric angle .theta. are substantially the same, and in a range
of less than about 45.degree.. The guide 622c functions to conform
the fabric 532 to the shape of the profile/stiffener combination
576. Such a configuration allows the guide to merely shape the
fabric, without significantly redirecting the fabric 532 from the
fabric angle .theta. to the approach angle .alpha., as a large
deviation between those two angles increases friction and may cause
undesired creasing or breakage of the fabric 532. In one
embodiment, this angle, .alpha.', is less than about 10.degree.
from the foam/stiffener combination. In other embodiments, the
angle .alpha.' may be less than about 5.degree.. This angle may be
maintained for distances up to and above about 5 feet to about 10
feet upstream of the fabric guide, to ensure a smooth transition of
the fabric onto the foam/stiffener combination. In certain
embodiments, the angle is maintained for distances of about 6 feet
to about 8 feet upstream of the coating die. In other embodiments,
the approach angle y maintained for several inches upstream of the
coating die.
[0079] FIGS. 16A-16L schematically depict cross-sections of various
embodiments of fabric-clad foam weatherstrip 630 manufactured in
accordance with the present invention. Embodiments of weatherstrip
made in accordance with the invention may include stiffeners and
foam profiles of virtually any configuration. For example,
generally linear and T-shaped stiffeners are depicted in FIGS.
16A-16L, but other shapes, with or without retention barbs are
contemplated. Similarly, cross sections of foam profiles may be of
any shape, including square, circular, L-shaped, trapezoidal, oval,
triangular, etc. Additionally, hollow foam profiles may be used, as
well as non-foam profiles. FIGS. 16A-16L are schematic depictions;
thus, the sizes, thicknesses, etc. of the various elements are not
to scale. Further, it should be understood that the various
depicted elements are generally shown spaced apart for clarity;
however, unless otherwise described, the elements are in mating
contact.
[0080] FIG. 16A depicts a weatherstrip 630 wherein the fabric layer
632 only partially covers the coating 634 and the foam profile 636.
The coating 634 includes portions 638 that overlap at least a
portion of the stiffener 640 to provide additional attachment of
the profile 636 to the stiffener 640. FIG. 16B depicts a fabric
layer 632 completely covering the exposed foam profile 636. The
edges 632a of the fabric 632 are covered by discrete portions 638
of the coating layer 634 to anchor the fabric 632 and prevents the
fabric edges 632a from releasing from the profile 636. FIG. 16C
depicts a fabric layer 632 completely covered by the coating 634 of
the weatherstrip 630. FIG. 16D depicts fabric 632 located solely on
the sides of the weatherstrip 630, above the coating 634, providing
reinforcement.
[0081] FIG. 16E depicts fabric 632 located on the sides of the
weatherstrip 630 and below the coating 634. In this embodiment, the
fabric 632 provides reinforcement even in the absence of bonding of
the foam profile 636 to the fabric 632. FIG. 16F depicts a
weatherstrip 630 similar to that depicted in FIG. 16E, but
including an adhesive layer 642 adhering the fabric 632 to the foam
profile 636. FIG. 16G depicts an embodiment of weatherstrip 630
having fabric 632 located above the coating 632, similar to that
depicted in FIG. 16A. The fabric 632 can be mechanically treated
with an abrasive (e.g., a wire wheel) to scuff the fabric 632. The
scuffed surface 644 of fabric 632 may provide increased cushioning,
sealing thickness, an improved seal against irregular surfaces, and
may further reduce friction. FIG. 16H depicts a weatherstrip 630
utilizing the coating 634 to hold the fabric 632 against the foam
profile 636, without completely surrounding the foam profile 636.
The fabric 632 may still be utilized on a portion of the foam
profile 636, with or without the use of adhesive.
[0082] FIG. 16I depicts an embodiment of weatherstrip 630 having an
irregular shape with fabric 632', 632'' in two different locations.
The fabric 632' located on the outer top curvature of the profile
636 prevents tearing of the profile 636 and reduces friction. The
fabric 632'' on the inside corner of the profile 636 may act as a
hinge, whether supported along its width by the skin 634, or
free-floating. FIG. 16J depicts an embodiment of the weatherstrip
630 utilizing a ribbed or striated fabric 644, which may provide
additional sealing against irregular surfaces, friction resistance,
etc. The ribs 644' may be formed in the fabric 644; alternatively,
ribs of low friction coating can be applied to spaced locations on
the fabric.
[0083] FIG. 16K depicts an embodiment of the weatherstrip 630
wherein a pleat 646' is present in the fabric 646 create a sealing
wand 648. Alternatively or additionally, materials may also be
extruded onto the fabric layer to create sealing wands or fins.
FIG. 16L depicts another embodiment of the weatherstrip 630, where
the coating layer 634 partially overlaps the edges 632a of the
fabric 632. In this embodiment, and in other embodiments where the
coating does not completely cover the fabric, the coating layer may
overlap the fabric layer at its edges as desired for a particular
application. Manufacturing tolerances may dictate the minimum
required overlap, z, but overlaps of about 0.03 in. to about 0.06
in. are typical. Larger overlaps may be desired for applications
that require more robust adhesion of the fabric or where shear
loading of the fabric is experienced in use, but where complete
overlap of the fabric is not required. In certain embodiments
overlaps of up to about 0.2 in. are utilized.
[0084] Other types of seals 660 can benefit from application of a
fabric layer, as depicted in FIG. 17. For example, silicone or
rubber profiles 662 (either solid or hollow) can have a fabric
layer 664 applied thereto, as depicted in FIG. 17. The core void
666 of the depicted hollow profile 662, can be pressurized or
supported on a mandrel when the fabric layer 664 is applied to
provide support, if desired. Additionally, the fabric cover layer
may be applied to all or part of the outer surface of the bulb
and/or stiffener, utilizing many of the same processes described
herein for manufacturing foam weatherstrip, modified as needed for
hollow extruded bulb applications. The fabric layer may almost
entirely surround the profile 662, and may be secured only at the
stiffener 668. Generally, the barbs 670 in such an embodiment
remain exposed in the finished weatherstrip. The coating layer 634
can be applied over, under, or solely along the edges of the fabric
layer 664
[0085] In instances where the fabric layer is only bonded to the
profile at the edges, and/or where the coating layer does not fully
encapsulate the foam profile, weatherstrip performance properties
can be improved. FIGS. 18A-18B depict an example of a weatherstrip
700 made in accordance with the present invention. The weatherstrip
700 includes a stiffener 702 having a barbed extension 704. A foam
profile 706 is secured to the stiffener 702 along its base. A
coating layer 708 is applied to and extends a distance D along the
sides of the profile 706. A fabric layer 710 covers the profile
706, and is secured only at its edges 712 by the coating layer 708.
FIG. 18A shows the weatherstrip 700 in a neutral or unstressed
position. When a force F is applied to the top of the weatherstrip
700, as depicted in FIG. 18B, the weatherstrip 700 is deformed.
This deformation may occur as a result of a window or door closing
against the weatherstrip 700. As the weatherstrip 700 deforms, the
foam profile 706 is compressed (outline 714 shows the shape of the
weatherstrip 700 prior to the application of force F). As the foam
profile 706 compresses, the fabric layer 710 separates from the
profile 706, forming gaps 716 between the profile 706 and the
fabric 710. In foam profiles, these gaps 716 expose an internal
surface area of the profile 706 (essentially along the entire
length of the weatherstrip 700), that allows for improved air
movement in the weatherstrip 700, enabling faster compression at
lower resistance and correspondingly faster recovery when the force
F is removed. This feature provides for enhanced performance and
sealing effectiveness. In embodiments of the weatherstrip 700
configured as depicted, the profile 706 may deflect significantly,
without corresponding deformation in the coating 708. Some minimal
spread S of the profile 706 to the sides of the weatherstrip 700
may occur, but it is generally limited to a range that does not
causes excessive wear on the weatherstrip 700 or individual
elements.
[0086] FIGS. 18C-18D depict another weatherstrip 700', having a
stiffener 702' with a barbed extension 704' produced in accordance
with another embodiment of the invention. The foam profile 706' is
fully coated by the coating layer 708' with a fabric layer 710' on
top. As depicted, weatherstrip 700' is dimensionally similar to
weatherstrip 700 when in the neutral position. Application of force
F' against the weatherstrip 700' is depicted in FIG. 18D. As the
force F' is applied, the weatherstrip 700' deforms along its
length. As the weatherstrip 700' deforms, the foam profile 706' is
compressed (outline 714' shows the shape of the weatherstrip 700'
prior to the application of force F'). Unlike the weatherstrip 700
utilizing an unadhered fabric layer 710, the coating 708' cannot
separate from the deforming foam profile 706'. Depending on the
thickness and stiffness of the coating 708', bulges 718 can form on
the outer surface of the weatherstrip 700'.
[0087] As known to those of ordinary skill in the art, compression
load deflection (CLD) curves are important in determining
suitability of foam weatherseals in fenestration applications. As
depicted, the weatherstrip 700 of FIG. 18B typically can be
compressed further than the weatherstrip 700' of FIG. 18D, under a
similar load. This improved compression load deflection performance
is, therefore, highly desirable in applications such as window and
door seal applications. Further, compression set and compression
force can be reduced, because the foam can compress free of any
surface constraints caused by a continuous surface layer of coating
or fabric. Weatherstrip drag or friction can also be reduced, since
the fabric layer can shift or move relative to the underlying foam
profile. Sealing can also be improved, since the fabric layer can
have a tendency to widen and flatten, when the foam profile is
compressed. Sealing application that require more robust sealing,
however, nonetheless can benefit from the fully encapsulated and
attached foam profile.
[0088] The process of applying fabric to the inside or outside of
the skin or coating layer of a weatherstrip utilizes any of the
coated weatherstrip manufacturing processes described above. The
manufacturing process may include a series of thermoplastic resin
extruders laid out in a sequential pattern, so as to optimize the
efficiency of applying sequential components and layers of
polymeric material to the product. Thermal bonding may be used
advantageously in order to join the components together to produce
a complex weatherstrip structure in cross sectional profile, but
with an infinite length. The extruder locations can be configured
to optimize the ability of a single operator to see and monitor the
controls, speeds, and output of the entire line, and to make
adjustments according to product and process requirements. The foam
profile production process rate is controlled by the conveyor
speed, the stiffener rate by the first puller speed, and the coated
combined product by the second puller speed, thus balancing the
system so that the output from each extruder is matched with the
line's output speed. This is accomplished by a combination of
tension, loop control, and extruder output. In the alternative,
foam and/or stiffener components can be pre-extruded and stored on
reels or bins and fed into the coat die, increasing material
handling and storage, but reducing size of the floor layout for the
production line.
[0089] Settings for one embodiment of a weatherstrip manufacturing
apparatus (such as an embodiment of the apparatus depicted in FIG.
11) are depicted in Table A, below. This exemplary process line
utilizes extruders for the foam profile, stiffener (which may be
co-extruded with barbs), and weatherstrip coating or skin. One
advantage of the process disclosed herein is that the fabric
application may occur without significant modifications to the
process line settings, allowing for an efficient and cost effective
change-over in production of coated weatherstrip to the
fabric-reinforced weatherstrip disclosed herein. In the Table, the
Additive Feeder and Extruder Speeds are dial settings. The screens
are utilized in the extrusion process. Dual screen systems are used
for various sizes (e.g., 14 openings/in. and 40 openings/in.).
TABLE-US-00001 TABLE A Process Line Settings FOAM EXTRUDER Additive
Feeder: 200 Profile: Zone 1: 300.degree. F. Zone 2: 330.degree. F.
Zone 3: 350.degree. F. Zone 4: 350.degree. F. Zone 5: 350.degree.
F. Zone 6: 350.degree. F. Zone 7: 345.degree. F. Zone 8:
340.degree. F. Clamp: 365.degree. F. Die: 365.degree. F. Water
Injection: 3.8 ml/min; Extruder Speed: 275; Conveyer Speed: 60
ft/min; Screens: 14/40 STIFFENER EXTRUDER Profile: Zone 1:
390.degree. F. Zone 2: 440.degree. F. Zone 3: 440.degree. F. Die 1:
450.degree. F. Die 2: 450.degree. F. Extruder Speed: 1000; Puller
Speed: 60.4 ft/min; Screens 14/40 BARB EXTRUDER Profile: Zone 1:
390.degree. F. Zone 2: 440.degree. F. Zone 3: 440.degree. F.
Adapter: 450.degree. F. Die 1: 450.degree. F. Extruder Speed: 440;
Screens: 14/40 COATING EXTRUDER Profile: Zone 1: 350.degree. F.
Zone 2: 400.degree. F. Zone 3: 445.degree. F. Die 1: 445.degree. F.
Die 2: 440.degree. F. Die 3: 445.degree. F. Extruder Speed: 815;
Puller Speed 60.6 ft/min; Screens 14/40
[0090] The layout of the stiffener die is generally in-line with
the coating die and hot-melt adhesive applicator, with the foam
being carried into the path of the stiffener from a right-angle
approach. Likewise, the direction of resin flow supplying the coat
die is at about a 90-degree angle from the stiffener, but other
arrangements are also contemplated. For an efficient use of floor
space, the coating resin extruder can be placed parallel with the
stiffener extruder with an elongated adaptor with an "S" channel
situated therein, allowing, on the inlet end, a means of attaching
the adaptor to the face of the coat extruder exit face plate by
mounting screws set in a circular fashion. In one embodiment, a
pipe fitting is attached at the die end of the "S" channel which is
in turn attached to the inlet of the coat die. By the use of this
offset adaptor plate, the coat die is mounted offset to the coat
extruder, conserving floor space and allowing a single operator to
run the line. This also allows the foam conveyor, which is required
to gradually cool the foam to nearly ambient surface temperature,
to extend parallel to, but behind, the coat extruder, giving the
operator good visibility and control over the foaming process. The
offset adaptor plate positions the coating resin extruder away from
the location where the fabric is applied, whether it is at the foam
conveyor, before the coating die, or after the coating die. The
offset adaptor plate can be further adapted to accommodate any
changes that may be required to make room for the addition of
guides, rollers, heaters, or the like for application of the
fabric.
[0091] In certain applications, foam is reeled under predetermined
tension and orientation, and unwound from the reel and combined
with polyethylene film utilizing guidance and tension control
methods. In these applications, guidance and tension control can be
used to more effectively feed the release liner film onto the
product downstream of the coat die. Alternatively, foam and
finished product is wound onto reels in a controlled manner,
stored, and sold for use as finished product. The replacement of a
standard mechanical "dancer arm" method of driving the rotary
motion of a reel-up machine with the an ultrasonic pulse generator
to sense the slack loop required to maintain proper reel-up tension
control helps prevent damage to the foam products.
[0092] Additionally, a preheating or corona treatment stage may be
used on one or more substrates involved in the application of the
fabric. Warming plates, heat tunnels, hot air guns, and heat lamps
may be used to preheat adhesive backed film, foam, and stiffener
material to enhance the bond between components of weatherstripping
or other coated products. Further steps of applying heated air to
the stiffener in order to dry and preheat the product to enhance
the thermal adhesion may also be utilized. Corona treatment of
film, stiffener, and foam with Corotec corona discharge units may
enhance the adhesion properties as well. For fabric layers that are
treated with an adhesive coating, a preheating station of the types
described may be utilized prior to applying the fabric layer to the
foam profile or stiffener, to ensure a satisfactory bond.
Alternatively, the heat generated by the coating die itself or the
extruded foam or stiffener may help secure the fabric, depending on
the thermal properties of the adhesive used.
[0093] The shape of the extruded stiffener may also be controlled
by utilizing a single brass block with the shape of the product cut
along the length of the upper surface. This block may be fitted
into a holder attached to a vacuum apparatus to produce stiffener
profiles more precisely than have previously been achieved. A
series of slots may be cut by wire EDM in the sizer block so as to
hold the product lightly against the upper surface of the block as
it is pulled along its length. By controlling the vacuum, the
cooling of the molten stiffener may be accelerated while at the
same time being supported by the brass block, thereby creating a
superior product shape control process.
[0094] One embodiment of a process line 750 for manufacturing
fabric clad weatherstrip is depicted in FIG. 11. A foam extruder
752 extrudes the foam profile 754 using water as a blowing agent
onto one or more conveyers 756 where it obtains its final shape as
it cools. A stiffener extruder 758 extrudes the stiffener 760,
which is cooled in a water bath 762, while being pulled by a puller
764. Alternatively, an integral stiffener/barb element may be
manufactured utilizing a coextruder. An optional heating/drying
station 766 may be utilized to treat the extruded stiffener 760,
depending on the size or shape of the stiffener (e.g., large
extrusions may require one or more drying stations). The foam 754
and stiffener 760 are joined at a glue table 768, which is fed by a
glue machine 770. This combination foam/stiffener element 772 may
be passed through another heating/drying station 774, if
desired.
[0095] A fabric spool 776 dispenses fabric 778 along the distance
traveled by the combination foam/stiffener element 772. The fabric
778 is not attached to the combination foam/stiffener element 772
at the glue table 768, but passes generally above the table 768. As
described with regard to FIG. 15C, a small approach angle .alpha.;
accordingly, the fabric 778 travels near to parallel to the
combination foam/stiffener element 772 until it reaches the fabric
guide 776. After forming to the shape of the combination
foam/stiffener element 772, the uncoated weatherstrip passes
through the coating die 778, which is fed by the coating extruder
780. The finished coated weatherstrip 782 passes through a water
bath 784 to cool. An end puller 786 pulls the finished weatherstrip
to a reel or cut-up station 790 for final processing.
[0096] Fabric clad foam weatherstrip may also be manufactured using
ultrasonic welding in lieu of, or in addition to, the resin coating
application. One such ultrasonic welding station 800 is depicted in
FIG. 19. In this embodiment, the foam profile 802 and stiffener 804
have been joined and the fabric cover layer 806 applied to the foam
profile/stiffener combination. Instead of or in addition to using
the coating die (depicted in FIG. 11, for example) to secure the
fabric layer 806 to the foam profile/stiffener combination, one or
more ultrasonic welds are utilized to join the various components.
In the depicted embodiment, a foam profile 802 secured to a
T-shaped stiffener 804 is passed between two steel wheels 808 that
guide the stiffener 804 and hold the cover layer 806 in place. The
wheels 808 also press against the stiffener 804 and cover layer
806. The stiffener 804 passes over one or more ultrasonic horns
810, which form the weld between the components at locations 812.
Other configurations are possible, depending on which weatherstrip
elements are welded, where the welds are located, etc. Accordingly,
an ultrasonic welding station 800 may entirely replace the coating
die station in the process line depicted in FIG. 11. Alternatively,
the fabric layer may be secured utilizing continuous or
intermittent mechanical fastening systems (staples, stitching,
pressure rollers, etc.), thermal fusion, etc. Additional components
may be utilized to create a strong bond; for example, a layer of
thermally compatible material may be applied to facilitate a bond
generated by thermal fusion. After securing the fabric layer with
ultrasonic welding, mechanical systems, fusion, or other forms of
attachment, the weatherstrip may either by finished with a complete
or partial resin coating, or simply utilized without any resin
coating, depending on the application. In general, if resin coating
is used in addition to another form of attachment, the resin
coating station could be placed downstream from the alternative
attachment station, although certain types of alternative
attachment (e.g., mechanical fastening) may produce a satisfactory
product even if installed downstream from the resin coating
station.
[0097] The invention has been described in detail in connection
with the preferred embodiments. These embodiments, however, are
merely for example only and the invention is not limited thereto.
It will be appreciated by those skilled in the art that other
variations and modifications can be easily made within the scope of
the invention as defined by the appended claims.
* * * * *