Laminate of a substrate and an extruded high density polyethylene

• US 20010055663A1
• Filed: 12/13/2000
• Published: 12/27/2001
• Est. Priority Date: 01/04/2000
• Status: Active Grant

• Current Assignee: Cooper-Standard Automotive Incorporated (Cooper-Standard Holdings Incorporated)
• Original Assignee: The Standard Products Company (Goodyear Tire & Rubber Company)
• Inventors: Sheets, James Patrick, Mertzel, Elaine Audrey, Truskowski, John Walter
• Granted Patent: US 6,660,360 B2
• Time in Patent Office: Days
• US Class Current: 428/122
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2305/74 Partially cured
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2317/22 Natural rubber synthetic rubber B32B2319/00
• CPC Class Codes: B32B 2319/00 Synthetic rubber natural rubber B32B2317/22
• CPC Class Codes: B32B 2323/043 HDPE, i.e. high density polyethylene
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 2581/00 Seals; Sealing equipment; Gaskets
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B60J 10/15 characterised by the material
• CPC Class Codes: B60J 10/74 for sliding window panes, e.g. sash guides
• CPC Class Codes: B60J 10/75 for sealing the lower part of the panes
• CPC Class Codes: Y10T 428/24198 Channel-shaped edge component [e.g., binding, etc.]
• CPC Class Codes: Y10T 428/24975 No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/31826 Of natural rubber
• CPC Class Codes: Y10T 428/31909 Next to second addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31913 Monoolefin polymer
• CPC Class Codes: Y10T 428/31938 Polymer of monoethylenically unsaturated hydrocarbon

Abstract

A laminate of an elastomeric substrate and a high density polyethylene having certain properties is disclosed. The preferred high density polyethylene has a density of from 0.940 to 1.000 g/cm³, a melt index of less than 10 grams per 10 minutes under conditions of 190° C. and 2.160 kg load and 298.2 kPa, and a melt index of greater than 5 grams per 10 minutes under conditions of 190° C. and 21.6 kg load and 2,982.2 kPa pressure. The laminate is particularly well suited for use in automotive seals.

Claims

1. A laminate assembly adapted for use as a weatherstrip seal, said laminate assembly comprising:

an elastomeric substrate; and

a thin layer disposed on and affixed to at least a portion of said substrate, said layer having a thickness less than 500 microns and comprising polyethylene that exhibits a melt index of less than 10 grams per 10 minutes under conditions of 190 degrees centigrade and 2.160 kg total load and 298.2 kPa pressure, and a density of from about 0.940 to about 1.000 g/cm³.

2. The laminate of

claim 1

wherein said layer has a thickness of from about 1 micron to about 300 microns.

3. A laminate assembly adapted for use as a weatherstrip seal, said laminate assembly comprising:

an elastomeric substrate; and

a thin layer disposed on and affixed to at least a portion of said substrate, said layer having a thickness less than 500 microns and comprising polyethylene that exhibits a melt index of greater than 5 grams per 10 minutes under conditions of 190 degrees centigrade and 21.6 kg total load and 2982.2 kPa pressure, and a density of from about 0.940 to about 1.000 g/cm³.

4. The laminate assembly of

claim 3

wherein said layer has a thickness of from about 1 micron to about 300 microns.

5. A laminate product comprising (i) a substrate selected from the group consisting of natural rubber, synthetic rubber, thermoplastic polyolefins and thermoplastic vulcanizates and (ii) a high density polyethylene polymer layer disposed on said substrate, said polyethylene having a melt index of less than 10 grams per 10 minutes as determined by ASTM D-1238 under conditions of 190 degrees centigrade and 2.160 kg total load and 298.2 kPa pressure and a melt index of greater than 5 grams per 10 minutes under conditions of 190 degrees centigrade and 21.6 kg total load and 2982.2 kPa pressure.

6. The laminate product of

claim 5

wherein said polyethylene has a density of from about 0.900 to about 1.250 g/cm³.

7. The laminate product of

claim 5

wherein said polyethylene has a density of from about 0.940 to about 1.000 g/cm³.

8. The laminate product of

claim 5

wherein said layer of polyethylene has a thickness less than 500 microns.

9. The laminate product of

claim 8

wherein said layer of polyethylene has a thickness of from about 300 microns to about 1 micron.

10. A glass run channel comprising a substrate and a high density polyethylene layer disposed on said substrate, said substrate selected from the group consisting of natural rubber, synthetic rubber, thermoplastic polyolefin and thermoplastic vulcanizates, and said polyethylene having a melt index of less than 10 grams per 10 minutes as determined by ASTM D-1238 under conditions of 190 degrees centigrade and 2.160 kg total load and 298.2 kPa pressure and a melt index of greater than 5 grams per 10 minutes under conditions of 190 degrees centigrade and 21.6 kg total load and 2982.2 kPa pressure.

11. The glass run channel of

claim 10

wherein said substrate defines a channel region and said layer of polyethylene is disposed in said channel.

12. The glass run channel of

claim 10

wherein said polyethylene has a density of from about 0.900 to about 1.250 g/cm³.

13. The glass run channel of

claim 10

wherein said polyethylene has a density of from about 0.940 to about 1.000 g/cm³.

14. The glass run channel of

claim 10

wherein said layer of polyethylene has a thickness less than 500 microns.

15. The glass run channel of

claim 14

wherein said layer of polyethylene has a thickness of from about 300 microns to about 1 micron.

16. The glass run channel of

claim 15

wherein said layer of polyethylene has a thickness of from about 200 microns to about 5 microns.

17. A belt weatherstrip comprising (i) a substrate selected from the group consisting of natural rubber, synthetic rubber, thermoplastic polyolefin and thermoplastic vulcanizate, and (ii) a high density polyethylene layer disposed on at least a portion of said substrate, said polyethylene having a melt index of less than 10 g per 10 minutes as determined by ASTM D-1238 under conditions of 190 degrees centigrade and 2.160 kg total load and 298.2 kPa pressure and a melt index of greater than 5 grams per 10 minutes under conditions of 190 degrees centigrade and 21.6 kg total load and 2982.2 kPa pressure.

18. The belt weatherstrip of

claim 17

wherein said polyethylene has a density of from about 0.900 to about 1.250 g/cm³.

19. The belt weatherstrip of

claim 17

wherein said polyethylene has a density of from about 0.940 to about 1.000 g/cm³.

20. The belt weatherstrip of

claim 17

wherein said layer of polyethylene has a thickness less than 500 microns.

21. The belt weatherstrip of

claim 20

wherein said layer of polyethylene has a thickness of from about 300 microns to about 1 micron.

22. A method of making an extruded laminate comprising:

coextruding (i) a substrate selected from the group consisting of synthetic rubber, natural rubber, thermoplastic polyolefin and thermoplastic vulcanizate, and (ii) a high density polyethylene polymer having a melt index of less than 10 grams per 10 minutes as determined by ASTM D-1238 under conditions of 190 degrees centigrade and 2.160 kg total load and 298.2 kPa pressure and a melt index of greater than 5 grams per 10 minutes under conditions of 190 degrees centigrade and 21.60 kg total load and 2982.2 kPa pressure.

23. The method of

claim 22

wherein said substrate comprises rubber and said method includes a subsequent step of curing said rubber.

24. The method of

claim 22

wherein said high density polyethylene has a density of from about 0.900 to about 1.250 g/cm³.

25. The method of

claim 22

wherein said high density polyethylene has a density of from about 0.940 to about 1.000 g/cm³.

26. The method of

claim 22

wherein said substrate of said extruded laminate is at least partially cured and then a layer of a high density polyethylene polymer is further extruded onto at least a portion of said laminate.