Manufacture of composite extrusions

• US 5,686,165 A
• Filed: 09/12/1996
• Issued: 11/11/1997
• Est. Priority Date: 11/21/1988
• Status: Expired due to Term

• Current Assignee: Metzeler Automotive Profile Systems Limited
• Original Assignee: Schlegel (UK) Holdings Limited
• Inventors: Cook, John Edward
• Primary Examiner(s): Epstein, Henry F.
• Application Number:
  US08/714,031
• Time in Patent Office: 425 Days
• Field of Search: 428/31, 428/122, 428/358, 49/490.1, 52/716.5
• US Class Current: 428/122
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/155 Partial coating thereof
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/22 with means connecting the layers, e.g. tie layers or undercuts
• CPC Class Codes: B29C 48/304 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29K 2301/10 Thermosetting resins
• CPC Class Codes: B60J 10/15 characterised by the material
• CPC Class Codes: B60J 10/16 consisting of two or more plastic materials having different physical or chemical properties B60J10/17 takes precedence
• CPC Class Codes: B60J 10/17 provided with a low-friction material on the surface
• CPC Class Codes: B60J 10/24 having tubular parts
• CPC Class Codes: B60J 10/246 having projections, e.g. ribs, within the tubular parts
• CPC Class Codes: B60J 10/265 the surface being primarily decorative
• CPC Class Codes: B60J 10/33 characterised by the configuration of the retaining lips
• CPC Class Codes: B60J 10/76 for window sashes; for glass run channels
• CPC Class Codes: B60J 10/80 specially adapted for opening panels, e.g. doors for non-fixed roofs B60J10/90
• CPC Class Codes: Y10T 428/24198 Channel-shaped edge component [e.g., binding, etc.]
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/2902 : Channel shape
• CPC Class Codes: Y10T 428/31707 : Next to natural rubber
• CPC Class Codes: Y10T 428/31917 : Next to polyene polymer

Abstract

A method of forming a composite extrusion is disclosed wherein a main body portion (1) of the extrusion is first extruded from a thermosetting material, this body portion then being heated so as at least partly to cure it, the main body portion then being passed at high temperature through a further extruder where a thermoplastics material (8) is extruded onto one or more surfaces of the main body portion (1), the subsequent composite extrusion then being cooled and formed into its final shape. It is important that the combining step be undertaken at a temperatue high enough to cause the thermoplastics material to bond to the thermosetting material and while it is simplest for the thermoplastics material to be on an outer surface of the composite extrusion, it is possible for it to be located within the thermosetting material by extruding the thermosetting material in an "opened out" state and then after extruding the thermoplastics and while the extrusion is still hot, folding in edge regions of the main body to overlie the thermoplastics material and bond thereto. The thermoplastics material may be of a special color, may be embossed, and if it is located within the thermosetting material in the end product, may be stiffer than the latter. The invention also extends to the extrusions themselves.

Claims

1. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded thermosetting polymeric material, having encapsulated therein a generally U-shaped knitted wire carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting material, the thermoplastic material having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting main body.

2. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded vulcanized polymeric material, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the vulcanized polymeric material, the thermoplastic material having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped vulcanized main body.

3. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from a thermosetting cross linked rubber, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting cross linked rubber, the thermoplastic material having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting cross linked rubber main body.

4. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded thermosetting polymeric material, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening and a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting material, the thermoplastic material being selected from the group consisting of polyethylene, polypropylene and ethylene vinyl acetate, the thermoplastic material having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting main body.

5. The composite extrusion of claim 4 in which the thermoplastic polymer material comprises one or more of calcium carbonate, mica, talc and plasticizers incorporated in the thermoplastic polymer.

6. The composite extrusion of claim 4 in which the thermoplastic polymer material is modified with EPDM.

7. The composite extrusion of claim 4 in which the thermoplastic polymer material is modified with butyl compounds.

8. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded cured EPDM rubber, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of an EPDM modified polypropylene bonded to the cured EPDM rubber, the EPDM modified polypropylene having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped cured EPDM rubber main body.

9. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded thermosetting polymeric material, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting material, the thermoplastic material having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting main body, the gripping fins comprising a plurality of small gripper fins.

10. The composite extrusion of claim 9 in which the thermosetting gripping fins comprise a large gripper fin disposed on an opposite inside surface of an arm of the U-shaped thermosetting main body from the plurality of small gripper fins.

11. The composite extrusion of claim 10 comprising a layer of soft polymeric material on an end of the large gripper fin.

12. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded thermosetting polymeric material, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing bulb attached to an outside wall of the U-shaped thermosetting main body;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting material, the thermoplastic material having a color selected in accordance with the color of the motor car; and

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting main body.

13. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded thermosetting polymeric material, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting material, the thermoplastic material having a color selected in accordance with the color of the motor car;

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting main body; and

a secondary seal attached to an end of a leg of the U-shaped thermosetting main body.

14. The composite extrusion of claim 13 in which the secondary seal has a subsidiary sealing fin.

15. The composite extrusion of claim 13 in which the secondary seal and the subsidiary sealing fin comprise a thermosetting polymeric material.

16. A composite extrusion for use as a combined edge trim and door seal for a motor car comprising:

a U-shaped main body formed from an extruded thermosetting polymeric material, having encapsulated therein a generally U-shaped metallic carrier for gripping a flange around a door opening; and

a hollow thermosetting sealing portion;

at least one outer surface portion on the main body formed of a thermoplastic polymer material bonded to the thermosetting material, the thermoplastic material having a color selected in accordance with the color of the motor car;

thermosetting gripping fins on inner surfaces of arms of the U-shaped thermosetting main body; and

a flap seal attached to the U-shaped thermosetting body, the flap seal comprising a first layer of thermosetting polymeric material and a second layer of thermoplastic polymer material.

17. The composite extrusion of claim 16 in which the flap seal is attached to the U-shaped thermosetting body at a first end and has a second free end extending away from the U-shaped main body.

18. The composite extrusion of claim 17 in which the second layer extends over the surface of the flap seal and at least a portion of the base of the U-shaped main body.