US20070028987A1 - Carrier Assembly with Fused Powder and Frame-Warp Aperture - Google Patents
Carrier Assembly with Fused Powder and Frame-Warp Aperture Download PDFInfo
- Publication number
- US20070028987A1 US20070028987A1 US11/536,796 US53679606A US2007028987A1 US 20070028987 A1 US20070028987 A1 US 20070028987A1 US 53679606 A US53679606 A US 53679606A US 2007028987 A1 US2007028987 A1 US 2007028987A1
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- US
- United States
- Prior art keywords
- warp
- frame
- powder
- serpentine
- carrier assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/20—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting articles of particular configuration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J10/00—Sealing arrangements
- B60J10/15—Sealing arrangements characterised by the material
- B60J10/18—Sealing arrangements characterised by the material provided with reinforcements or inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J10/00—Sealing arrangements
- B60J10/30—Sealing arrangements characterised by the fastening means
- B60J10/32—Sealing arrangements characterised by the fastening means using integral U-shaped retainers
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/04—External Ornamental or guard strips; Ornamental inscriptive devices thereon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/06—Sealing strips
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/06—Load-responsive characteristics
- D10B2401/062—Load-responsive characteristics stiff, shape retention
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/03—Shape features
- D10B2403/031—Narrow fabric of constant width
- D10B2403/0311—Small thickness fabric, e.g. ribbons, tapes or straps
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/18—Outdoor fabrics, e.g. tents, tarpaulins
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
Definitions
- 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.
- 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.
- 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.
- drifting of the warp threads can cause air bubbles and exposure of the wire in the final product.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- FIG. 1 is a top plan view of a representative carrier assembly.
- FIG. 2 is a cross-sectional view of a vehicular weather strip incorporating a configuration of the carrier assembly.
- FIG. 3 is a top plan view of the serpentine frame having parallel limbs.
- FIG. 4 is a top plan view of the serpentine frame having curvilinear limbs and connecting regions.
- FIG. 5 is a top plan view of the serpentine frame having tapered connecting regions.
- FIG. 6 is a top plan view of the serpentine frame having faceted limbs and curvilinear connecting regions.
- 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.
- FIG. 8 is a top plan view of the serpentine frame having parallel limbs and a plurality warps interlaced with the frame.
- FIG. 9 as a top plan view of the serpentine frame having curvilinear shaped limbs and a plurality of warps interlaced with the frame.
- 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.
- FIG. 11 is an enlarged cross-sectional schematic view showing the fused powder encapsulating a portion of the serpentine frame and the warp.
- FIG. 12 is a schematic cross-sectional view of a fused powder on a portion of the serpentine frame engaging a warp.
- 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 .
- 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 .
- the vehicle strips can have any of a variety of configurations for engaging a vehicle, such as a flange engaging strip.
- 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 .
- 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).
- serpentine frame 20 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.
- 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.
- 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 .
- 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.
- the wire has a generally circular cross-section.
- the wire may have any of a variety of cross-sectional profiles, such as but not limited to obround, elliptical, faceted or triangular.
- 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).
- the wire is a low carbon steel wire or 301 stainless steel having a diameter of about 0.030 inches (0.76 mm).
- 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.
- 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.
- interlacing which includes but is not limited to knitting or stitching such as crocheting, sewing, weaving or threading.
- 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 .
- the frame-warp apertures 30 can have a variety of sizes.
- 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).
- 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.
- 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 .
- 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.
- 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 .
- 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.
- 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 .
- 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 .
- 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 .
- 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.
- 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 .
- 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.
- the fused powder 60 slightly extends into the frame-warp aperture, and occludes a portion of the aperture.
- 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.
- the remaining frame-warp apertures 30 are of a sufficient area to preclude occlusion, thereby preserving at least one frame-warp aperture.
- 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 .
- 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 .
- 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).
- 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 .
- 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.
- 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.
- 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.
- 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 .
- thermoplastic powder is polyethylene, having a melting point below a melting point of the serpentine frame 20 and the warp 40 .
- the thermoplastic powder has a melting point of approximately 120° C.
- 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.
- a thermosetting resin having an epoxy group that is, glycidyl group
- epoxy resins acrylic resins
- acrylic resins are available.
- 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° C. to 260° C. It is understood any of a variety of cross-linking agents can be employed.
- 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.
- 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
- Suitable powders to be fused are sold by Morton Powder Coating of Warsaw, Ind. and include DG-5001 CORVEL® BLUE (ethylene/Acrylic), DG-7001 CORVEL® BLACK 20 (Ethylene/Acrylic), 78-7001 CORVEL® BLACK (Nylon) and 70-2006 CORVEL® YELLOW (Nylon).
- the fused powder 60 can be selected to promote bonding with the embedding material of the subsequent vehicular strip 12 .
- the powder includes a methacrylate coagent or a maleate.
- 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.
- 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.
- 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.
- 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.
- 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.
- the amount of powder retained on the one of the serpentine frame 20 and the warp 40 can be controlled.
- 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.
- 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.
- 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 .
- 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 .
- a contact device such as a roller can also be employed to deposit the powder onto the frame 20 and the warp 40 .
- 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 .
- 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.
- 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.
- 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 .
- 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 .
- 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.
- 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.
- 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 .
- the fused powder 60 can be bonded to the warp 40 prior to interlacing with the filament.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 .
Abstract
Description
- 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.
- Not applicable.
- Not applicable.
- 1. Field of the Invention
- 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.
- 2. Description of Related Art
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
-
FIG. 1 is a top plan view of a representative carrier assembly. -
FIG. 2 is a cross-sectional view of a vehicular weather strip incorporating a configuration of the carrier assembly. -
FIG. 3 is a top plan view of the serpentine frame having parallel limbs. -
FIG. 4 is a top plan view of the serpentine frame having curvilinear limbs and connecting regions. -
FIG. 5 is a top plan view of the serpentine frame having tapered connecting regions. -
FIG. 6 is a top plan view of the serpentine frame having faceted limbs and curvilinear connecting regions. -
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. -
FIG. 8 is a top plan view of the serpentine frame having parallel limbs and a plurality warps interlaced with the frame. -
FIG. 9 as a top plan view of the serpentine frame having curvilinear shaped limbs and a plurality of warps interlaced with the frame. -
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. -
FIG. 11 is an enlarged cross-sectional schematic view showing the fused powder encapsulating a portion of the serpentine frame and the warp. -
FIG. 12 is a schematic cross-sectional view of a fused powder on a portion of the serpentine frame engaging a warp. - A
carrier assembly 10 in accordance with the present invention is shown inFIG. 1 . Thecarrier assembly 10 includes aserpentine frame 20, at least onewarp 40 and a fusedpowder 60 on at least one of the frame and the warp to define at least one frame-warp aperture 30. - Referring to
FIG. 2 , thecarrier 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 thecarrier assembly 10 is shown inFIG. 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. - Serpentine Frame
- The
serpentine frame 20 has a plurality of transversely extendinglimbs 22 interconnected at alternate ends by connectingregions 24. Thelimbs 22 can be straight or curvilinear, and can define sections that are linear, faceted, banana shaped, propeller shaped or any combination thereof. Thelimbs 22 are in a generally parallel relationship, such as adjacent limbs ofFIGS. 1, 3 and 8, or alternating limbs are parallel as shown inFIGS. 4-7 and 9-10. Theserpentine frame 20 has a width defined by the connectingregions 24 at the end of thelimbs 22. - The
serpentine frame 20 can be described in terms of the number oflimbs 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). - Although the term “serpentine”
frame 20 is used, the serpentine frame is intended to encompass any frame construction, wherein thelimbs 22 and connectingregions 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. - 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. Theserpentine 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. - 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 theserpentine frame 20. - 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.
- 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).
- Referring to
FIGS. 1 and 8 -10, thewarp 40 extends along the longitudinal dimension of theserpentine frame 20. Thewarp 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. - The
warp 40 can be secured to theserpentine frame 20 by interlacing, which includes but is not limited to knitting or stitching such as crocheting, sewing, weaving or threading. Referring toFIGS. 1 and 8 -10, theframe 20 and thewarp 40 define a plurality of frame-warp apertures 30. The frame-warp apertures 30 have a periphery defined by theframe 20 and thewarp 40. Depending upon the interlacing of thewarp 40 and theframe 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 oflimbs 22 per inch (cm), the number ofwarps 40 and the interlacing configuration. - In one configuration, the
warp 40 encompass a portion of theserpentine frame 20 within a crocheted stitch. Thewarp 40 can be secured to theserpentine 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 inFIGS. 1 and 8 -10, is representative and that thewarp 40 can engage theserpentine frame 20 by any of a variety of constructions. - Depending upon the interlacing of the
warp 40 with theserpentine frame 20,intra-warp aperture 35 can also be formed as seen inFIG. 1 . Theintra-warp aperture 35 is defined by thewarp 40, rather than the warp and theserpentine frame 20. - 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 thewarp 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. - The fused
powder 60 is located on, and bonded to at least one of theserpentine frame 20 and thewarp 40. The fusedpowder 60 impedes or inhibits movement of thewarp 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 fusedpowder 60 constrains thewarp 40 relative to theserpentine frame 20. The resistance to movement of thewarp 40 relative to theserpentine frame 20 is created by contact between the warp and the fusedpowder 60. It is believed the contact between thewarp 40 and the fusedpowder 60 can be created by the fused powder bonding to theserpentine frame 20, the fused powder bonding to the warp, or the fused powder bonding the warp to the serpentine frame. - The amount of contact between the fused
powder 60 and thewarp 40 is sufficient to reduce or retard movement of the warp relative to theserpentine frame 20, and particularly movement of the warp along a length of thelimb 22. The contact between the fusedpowder 60 and thewarp 40 can be provided by the fused powder substantially encapsulating theserpentine frame 20 and thewarp 40. Alternatively, the fusedpowder 60 can be bonded to theserpentine frame 20, such as before thewarp 40 is interlaced, and thus contact the warp upon interlacing. It is also contemplated the fusedpowder 60 can be primarily bonded to thewarp 40. - In one configuration, the fused
powder 60 is on both thewarp 40 and theserpentine frame 20 and effectively locks the warp to a position on the frame. The amount of fusedpowder 60 can range from the encapsulation of at least a portion of one of theserpentine frame 20 and thewarp 40 seen inFIG. 11 , to a discontinuous (broken) sputtering seen inFIG. 12 . In all configurations, the amount of fusedpowder 60 is selected to substantially preserve the frame-warp aperture 30. - It is also contemplated the fused
powder 60 can be initially located on one of theserpentine frame 20 or thewarp 40, and subsequently remelted after interlacing the warp and the frame, so as to bond to both the warp and the frame. - In each configuration of the
carrier assembly 10, including the configuration of the fusedpowder 60 encapsulating at least one of theserpentine frame 20 and thewarp 40, at least a percentage of the total number of frame-warp apertures 30 is preserved. That is, the fusedpowder 60 coats the exposed surfaces of theserpentine frame 20 and thewarp 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 thecarrier 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 fusedpowder 60, without blocking all the apertures. The initial area of a given frame-warp aperture 30 and the amount of fusedpowder 60 are factors in determining the percentage of the original frame-warp apertures 30 that remain after application of the fusedpowder 60. - Thus, the fused
powder 60 can form a portion of the surface of theserpentine frame 20 or of the serpentine frame and thewarp 40, wherein at least one frame-warp aperture 30 is substantially preserved. In the encapsulation configuration for a given frame-warp aperture 30, the fusedpowder 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 thecarrier assembly 10 is preserved, with configurations of thecarrier 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 fusedpowder 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. - In a further configuration, the fused
powder 60 is bonded to primarily theserpentine frame 20, with a minimal or insignificant amount of powder bonded to thewarp 40. In this configuration, the fusedpowder 60 forms a rough surface on theserpentine frame 20, as seen inFIG. 12 , and does not encapsulate the frame, but rather forms local discontinuities or areas of fused powder. The roughness imparted by the fusedpowder 60 is sufficient to inhibit or impede lateral movement of thewarp 40 relative to theserpentine frame 20 andlimb 22. Typically, such roughness is less than the diameter of thewarp 40. Thus, for example, the fusedpowder 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 fusedpowder 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 thecarrier assembly 10. - 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 theserpentine frame 20, thewarp 40 and the fusedpowder 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. - Powders
- 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 fusedpowder 60 into a form that will not remelt. - 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. - A representative thermoplastic powder is polyethylene, having a melting point below a melting point of the
serpentine frame 20 and thewarp 40. In one configuration, the thermoplastic powder has a melting point of approximately 120° C. - 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° C.
- 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° C. to 260° C. It is understood any of a variety of cross-linking agents can be employed.
- 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.
- Suitable powders to be fused are sold by Morton Powder Coating of Warsaw, Ind. and include DG-5001 CORVEL® BLUE (ethylene/Acrylic), DG-7001 CORVEL® BLACK 20 (Ethylene/Acrylic), 78-7001 CORVEL® BLACK (Nylon) and 70-2006 CORVEL® YELLOW (Nylon).
- 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. - Thus, the fused
powder 60 can be constructed to retain thewarp 40 relative to theserpentine frame 20, preserve the frame-warp aperture 30, bond to the embedding material of the vehicular strip 12 and insulate the frame. - The fused
powder 60 is formed by retaining unfused powder on one of theserpentine frame 20 and thewarp 40, and then fusing the powder. The powder can be temporarily disposed on the one of theserpentine frame 20 and thewarp 40 by a variety of mechanisms including bonding agents, friction adhesion, or electrostatic attraction. - The bonding agents can be incorporated into the powder, or applied to the one of the
serpentine frame 20 and thewarp 40 in a desired location for the fusedpowder 60 prior to exposure of the frame and the warp to the powder. - Alternatively, a surface charge is formed on the one of the
serpentine frame 20 and thewarp 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. - To form the necessary surface charge on the one of the
serpentine frame 20 and thewarp 40, a potential is applied to the frame. It has been found that a sufficient potential can be applied to theserpentine frame 20 to create a charge sufficient to retain the powder prior to fusing. - 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 thewarp 40, the amount of powder retained on the one of theserpentine frame 20 and thewarp 40 can be controlled. As the amount of retained powder on the one of theserpentine frame 20 and thewarp 40 at least partially determines the thickness of the fusedpowder 60, the thickness of the fused powder can thus be controlled. - Alternatively, the
serpentine frame 20 and thewarp 40 can be passed through a bath, or fluidized bed of the powder to deposit the powder on the frame and the warp. The powderedserpentine frame 20 andwarp 40 can then be subject to a controlled vibration or air jet to remove excess powder. Alternatively, the powder can be vibrated with theserpentine frame 20 and thewarp 40 to deposit the powder. It is further contemplated that rollers can be used to deposit the powder on theserpentine frame 20 and thewarp 40. - Further mechanisms for depositing the powder onto the
serpentine frame 20 and thewarp 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 theserpentine frame 20 and thewarp 40. The spray method can also involve imparting a charge to the powder, which is then electrostatically attracted to one of theserpentine frame 20 and thewarp 40. Alternatively, a contact device, such as a roller can also be employed to deposit the powder onto theframe 20 and thewarp 40. - 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 fusedpowder 60 to theserpentine frame 20 or thewarp 40 is sufficient to inhibit movement of the warp relative to thelimb 22. - 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 afinished carrier assembly 10 take-up apparatus. Heating above the melting point of the meltable (or curable) powder causes the powder to bond to theserpentine frame 20 and/or thewarp 40. On cooling, the melted powder hardens and thewarp 40 is bonded in position. In one configuration, thewarp 40 is bonded to theserpentine frame 20 and locked in a given position. In a different configuration, the fusedpowder 60 forms the roughened surface on theserpentine frame 20 which engage thewarp 40. Thecarrier assembly 10 has a flat profile, is longitudinally stable and is virtually free of warp drift. - 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 theserpentine frame 20. Generally, the heating of theserpentine frame 20, thewarp 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 theserpentine frame 20, thewarp 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 theserpentine frame 20, thewarp 40 and the powder with infra-red radiation. A further method comprises passing theserpentine frame 20, thewarp 40 and the powder over a heated roller. Another method contemplates induction heating of theserpentine frame 20. In yet another configuration, the heatedserpentine frame 20, thewarp 40 and the powder are passed between forming rolls. The roll treatment can also help to maintain the flat profile of thecarrier assembly 10. The roll forming treatment can be applied during the heating process or immediately after the powder is fused. - 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. - In contrast to powder coating the
serpentine frame 20 interlaced with thewarp 40, it is contemplated the fusedpowder 60 can be bonded to the filament prior to interlacing thewarp 40. That is, the fusedpowder 60 is bonded to the filament, and the coated filament is formed into the serpentine frame and interlaced with thewarp 40. The fusedpowder 60 thus mechanically engages thewarp 40 and bonds to theserpentine frame 20. - In a further configuration, it is contemplated the fused
powder 60 can be bonded to thewarp 40 prior to interlacing with the filament. - Therefore, the process can include powder coating the
serpentine frame 20 and the interlacedwarp 40, interlacing the warp with a powder coated serpentine frame or interlacing a powder coated warp with the serpentine frame. - It is further contemplated that for thermoplastic fused
powders 60 on one of the filament or thewarp 40 prior to interlacing, the fused powder can be reheated after interlacing to induce the powder to fuse bond to the remaining component. - The invention provides a strong, physically and chemically
stable carrier assembly 10, essentially free of warp drift which allows close grouping and selective positioning ofadjacent 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. - It is also contemplated the amount of fused
powder 60 can be selected to reduce or minimize de-spragging of thecarrier assembly 10. That is, absent the fusedpowder 60, upon cutting theserpentine 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 thecarrier assembly 10. It is believed the fusedpowder 60 can provide sufficient retentive force on thecarrier assembly 10 to substantially preclude the free end of the serpentine frame 20 (the filament) pulling from thewarp 40. Thus, the previously required step of de-spragging thecut carrier assembly 10 is obviated. - In addition, it is believed the fused
powder 60 on thewarp 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 thecut 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. - 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. Thecarrier 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. Thecarrier assembly 10 provides for positioning of thewarp 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. - 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 thecarrier assembly 10 is typically a polymeric material, such as for example, a thermoplastic or thermosetting elastomer. Generally, thecarrier assembly 10 is fed through an extruder, wherein a polymeric material is extruded about thecarrier assembly 10 so as to embed the carrier assembly within the polymeric material. To provide satisfactory embedding of thecarrier 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 thecarrier assembly 10. - 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.
Claims (20)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/536,796 US20070028987A1 (en) | 2005-02-09 | 2006-09-29 | Carrier Assembly with Fused Powder and Frame-Warp Aperture |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US11/054,485 US20060177627A1 (en) | 2005-02-09 | 2005-02-09 | Carrier assembly with fused power and frame-warp aperture |
US11/536,796 US20070028987A1 (en) | 2005-02-09 | 2006-09-29 | Carrier Assembly with Fused Powder and Frame-Warp Aperture |
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US11/054,485 Division US20060177627A1 (en) | 2005-02-09 | 2005-02-09 | Carrier assembly with fused power and frame-warp aperture |
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US20070028987A1 true US20070028987A1 (en) | 2007-02-08 |
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US11/349,754 Abandoned US20060177628A1 (en) | 2005-02-09 | 2006-02-08 | Carrier assembly with fused powder and frame-warp aperture and embedding composite strip |
US11/536,796 Abandoned US20070028987A1 (en) | 2005-02-09 | 2006-09-29 | Carrier Assembly with Fused Powder and Frame-Warp Aperture |
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US11/349,754 Abandoned US20060177628A1 (en) | 2005-02-09 | 2006-02-08 | Carrier assembly with fused powder and frame-warp aperture and embedding composite strip |
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US20120223542A1 (en) * | 2011-03-01 | 2012-09-06 | Nishikawa Rubber Co., Ltd. | Opening seal for automobiles and method of preparing the same |
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US20070245634A1 (en) * | 2006-03-23 | 2007-10-25 | Toyoda Gosei Co., Ltd. | Weather strip |
ITTO20070072A1 (en) * | 2007-02-01 | 2008-08-02 | Filmar S R L | GASKET REINFORCEMENT. |
US8768778B2 (en) * | 2007-06-29 | 2014-07-01 | Boku, Inc. | Effecting an electronic payment |
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Cited By (2)
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US20120223542A1 (en) * | 2011-03-01 | 2012-09-06 | Nishikawa Rubber Co., Ltd. | Opening seal for automobiles and method of preparing the same |
US8870258B2 (en) * | 2011-03-01 | 2014-10-28 | Nishikawa Rubber Co., Ltd. | Opening seal for automobiles and method of preparing the same |
Also Published As
Publication number | Publication date |
---|---|
WO2006086033A1 (en) | 2006-08-17 |
US20060177628A1 (en) | 2006-08-10 |
US20060177627A1 (en) | 2006-08-10 |
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Owner name: SCHLEGEL CORPORATION, NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:WHITEHEAD, WILLIAM;REEL/FRAME:018330/0582 Effective date: 20050209 |
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Owner name: BANK OF AMERICA, N. A., ILLINOIS Free format text: SECURITY AGREEMENT;ASSIGNOR:SCHLEGEL CORPORATION;REEL/FRAME:019920/0304 Effective date: 20070914 Owner name: BANK OF AMERICA, N. A.,ILLINOIS Free format text: SECURITY AGREEMENT;ASSIGNOR:SCHLEGEL CORPORATION;REEL/FRAME:019920/0304 Effective date: 20070914 |
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