SYSTEMS AND METHODS FOR MANUFACTURING REINFORCED WEATHERSTRIP

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and incorporates by reference herein in its entirety U S. Provisional Patent Application Serial No, 60 780,99 1 , fi led on March 1 0, 2006

TECHNICAL FIELD

[0002] The present inv ention generally relates to methods, s> stems, and apparatus for fabricating a fabπc-reinforced (clad) coated foam substrate, and the products manufactured b) the disclosed methods. s> stems, and apparatus

BACKGROUND OF THE INVENTION

[0003] Non-reinforced coated substrates may be manufactured b> a number of methods, as described w ith reference to FIGS. 1 - 10 and in the accompam ing text The methods and systems associated w ith the manufacture of non-reinforced coated substrates are also described in U.S. Patent 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 b) reference herei n in their entireties

[0004] In many applications, it is desirable to pro\ ide a relatn els thin, outer las. er or skin for a substrate, which ma) be a rigid or non-rigid foam profile or other material The substrate ma> include a plurality of components, some rigid and some nonπgid The la> eι or skin may perform a \ ariety of functions, such as protecting the substrate from adverse external conditions, prodding the external surface of the substrate oi portions thereof with characteristics sui table for particular applications, prov iding an aesthetically appeal ing finished product, and the like The outer lav er or skin ma\ 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 ma) include an outer Ia;. er or skin is a weatherseal or weatherstrip, embodiments of which are described herein, how ever, the method and apparatus described herein are not limited in this respect, indeed, it is broadl) appl icable Vv here it is desired to provide an outer las er or skin for ri gid and non-π gid substi ates inc luding, but not limited to. foams, metals, and previous!} extruded plastics

[0005] In general, weatherseals seal joints or spaces around doors and w indow s so as to inhibit infiltration of air, rain, snow, and other elements. Effectn e vs eatherseal s can reduce both heating costs in w inter and cooling costs in summer Certain characteristics are desirable to produce an effecti\ e w eatherseal. First, a w eatherseal should ha\ e good compression set resistance. Compression set resistance refers to the abilits of a material to resume its initial shape after being subjected to a compressi% e load Failure to resume this initial shape result in an uneven seal and reduce the effecth eness of the weatherseal Second, a w eatherseal should be soft and yielding, i.e . it should be easily compressible and conform to irregular surfaces. The gaps in doors, window s and the like in which w eatherseals are uti lized differ in size due to construction and other factors, and a w eatherseal should hav e sufficient compressibility to conform to a w ide range of gap sizes. Compressibility also ensures that a door or window, for example, can be closed w ithout excessive force and still compress the w eatherseal sufficiently to form the necessan seal .

[0006] The prior art discloses man) materials which are utilized as w eatherseals L ¹ . S Pat Nos, 4,32S,273 and 4.185,416 disclose the use of urethane foams for a w eatherseal Commonh assigned U S. Patent Nos. 4,89S,760. 5.192.586. 5.393 ,796. 5.5 12.601 , 5.607.629. 5.654,346. 5.728,406, and 5.788.889, the disclosures of w hich are incorporated herein bv

reference in their entireties, disclose the use of a low density foamed thermoplastic elastomer for a weatherseal. Howev er, these and similar mateπals may ha\ e relatively high coefficients of friction and may be easily damaged Thus, their effectiveness and utilits as a w eatherseal mas be reduced. These problems are magnified where the vs eathcrseal is subjected to sliding contact or other abrasiv e forces, thus, a method of manufacturing a w eatherstrip hav ing reduced frictional characteristics when sliding against a surface is desirable.

[0007] In order to alleviate the problems described abos e, an outer las er or skin is tv pically prov ided for the weatherseal. The outer lav er general Is has a low coefficient of friction relative to the surface of contact to facilitate relativ e motion and mav be generalls flexible to permit compression of the underlying seal The outer lav er also protects the seal from rips and tears caused bv sliding contact or other abrasiv e forces. Loss friction mateπals such as polyethv lene copolv mers. polv v inylchloride. and polv props lene copolv mers has e been utilized in the prior art for this outer las er.

[0008] There are sev eral disadv antages, however, associated with pres iding these loss friction outer lav ers Attaching the outer layer to the underlv ing 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 lav er can propagate into a much larger tear, adv ersely affecting the effectiveness and utility of the weatherseal Additionally, crosshead extrusion apparatus generalls requires complex arrangements of equipment and expensive dies These factors also increase production costs

[0009] One prior art technique proudes an outer skin for a substrate bs melting a resin and placing the melted resin in a tank or pool w ith an entrance opening and an exit opening The substrate is then pulled or dragged through the melted resin The exit opening sen es as a doctor blade to configure the outer layer How ever, it is difficult to precisely control the thickness of the outer layer or to selectn coat portions of the substrate utilizing this prior art technique Also, it is difficult to pro\ ide an outer layer of \ an ing thickness Finalh . the pressure and drag exerted on a non-rigid substrate such as a foam b> a viscous melted resin deforms and stretches the non-rigid substrate and generates a low qualits product

SUMMARY OF THE INVENTION [0010] Notw ithstanding the benefits of substrates coated in accordance w ith the teachings of U S Patent No 5, 192.586. there exists a need for more robust coated substrates to e heretofore unprecedented performance characteristics FIGS 1 1 - 1 9 and accompam ing text describe embodiments of the present invention The methods descri bed m these figures mas be incorporated into the methods of manufacture described in the former figures to produce fabπc-remforced coated substrates The addition of a fabric las er or other reinfoi cing la> er ma> be desirable for additional reinforcement, cushioning, or sealing Certain fabrics has e been elements of w eatherstrip sealing products since their inti oduction i n the 1 9SO s. forming barriers against air and w ater infiltration as part of properl s appl ied ss indow and door ss stem designs The fabrics can contribute toss'ard quiet operation, low friction (low operating forces^ loss w ater and air penetration, puncture resistance, tear resistance, colorabiht\ , UV resistance and long-term s\ eatherabiht\ . chemical resistance, and thermal adhesion to olefin thermoplastic substrates

[0011] Fabric clad weatherstrip offers man> features such as design versatility w ith many skin options utilizing an extruded polymer thermoplastic vulcanizate (TPV). for similar applications Other performance characteristics ma\ also be enhanced b> varying the poh mer grade and the las ers of polymer added to the skin layers Qr the foam in order to solve specific application issues; however, some prior art solutions become cost prohibit e or unreliable to consider due to their complexity or raw material cost. One such challenge is the difficult) created by apph mg a weatherstrip in a meeting rail or in a jamb in a tilt double hung application, where lateral forces are generated on a highh flexible seal, causing it to tear [0012] In one aspect of this im ention. the benefits of tear resistant, low friction poh prop> lene fabric are combined w ith the compression set resistance of TPY foam to provide a product of superior performance, utilizing an industry-pro\ en TPY sealing component, w hile providing a cost effective production method of apph ing the fabric to the foam substrate The fabric can be utilized to fulh or partialis encapsulate the foam core, and the coating tie layer mas bond to the inside of the fabric and to the stiffener for structural integrity' and stability . In \ aπous embodiments, the fabric may be applied in strips to proN ide low friction areas, hinges, reinforced areas, chafe resistant areas, or color match areas in order to impart specific chaiacteristics to the product The underlying extruded las er of poh mer mas be simpls a bonding material, requiring no UV protection or low friction characteristics, that being pro\ ided by the exterior layer, or it ma)' be of lower cost material to simpls act as a tie er The fabric may ha\ e a secondary extruded layer extruded onto or along the edges to protect them from catching and lifting with use. The secondary las er can utilize poh ethy lene. TPY, thermoplastic elastomer (TPE), poh ester, polypropylene, acn lonitrite butadrene sts rene (ABS), polystyrene ethylene butadiene sty rene (SEBS), eths lene v m> l acetate or other suitable and thermally compatible material.

[0013] The teachings of the invention can be practiced i n many w aj s 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 ma\ be pre-heated to enhance the bonding to the skin by the use of directed hot air or a hot plate The fabric ma} ¹ tra% el o\ er a roller downstream of the die opening, the roller being adjustable to apph appropriate pressure against the molten skin to achie\ e a bond. An alternate e method is to attach a die plate to the front of the coat die w ith 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 las er immediately after the coat die plate. The fabric application plate mas utilize a profil e cavit> configured so as to exert pressure on only the part of the product w here the fabric is being applied, the rest of the area being relieved, so as not to interfere w ith the cooling of the remainder of the molten skin la} er

[0014 J 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 apph ing 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, prouding a reinforcing material, and passing at least a portion of the profile through a coating d ie to coat the profile with a resin, w herein the resin attaches the reinforcing material to the w eatherstrip In certain embodiments of the above aspect, the coating substantial!} co\ ers the reinfoi cing material

[0016] In another aspect, the invention relates to a weatherstrip ha\ ing. 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 abo\ e aspect, the reinforcing material is disposed between the foam profile and the coating la> er In other embodiments, the reinforcing material is disposed on an outer surface of the coating la\ er, and ma\ include a stiffener.

[0017] In another aspect, the inv ention relates to an apparatus for manufacturing coated w eatherstrip, the apparatus having a foam extruder, a stiffener roll, a coating die and coating extruder, and a puller. In certain embodiments of the abo\ e aspect, the apparatus includes a heat source, v% hich 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, w hich ma% be located at or near the outlet of the foam extruder, In certain embodiments, the applicator ma\ be located at the heat source, or it maj be located w here the stiffener is secured to the foam Alternate el> . the applicator be located bey ond the stiffener application location In other embodiments, the fabric applicator ma)' be integral \\ ith the coating die, or mav be located betv, een the coating die and the puller.

[0018] In another aspect, the invention relates to an apparatus for manufacturing coated weatherstrip, w herein the fabric applicator for securing the fabric to the extruded foam is a roller, the roller being used w ith 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 ma% sen e as the heat source. In certain embodiments of the abov e aspect, w here 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 ma}' be attached to the coating die with or without a thermal break.

[0019] Accordingly, it is an object of the present in\ ention to pro\ ide a method and apparatus for coating a substrate which is simple and relatn ely low in cost It is another object of the present invention to provide a method and apparatus for coating a substrate w hich produces a less oriented outer layer, It is still another object of the present ention to proN ide a method and apparatus for producing a substrate ha% ing a multiple-component outer la> er, It is stil l another object of the present invention to provide a method and apparatus for providing a substrate with an outer las er of varying thickness w hich ma> be selectively applied to portions of the substrate Il is still another object of the present im ention to overcome the disad\ antages of the prior art

[0020] In another aspect, the in\ ention relates to a method of making a w eatherstrip ing a foam profile, a resin coating, and a co\ er la} er, the method including the steps of providing the foam profile, providing the co\ er la} er, and passing the co\ er layer and the foam profile through a resin coating station, wherein at least a portion of the cover layer is coated with the resin, w hile the resin is in a substantially liquid state. In embodiments of the above aspect, the method also includes the step of applying the co\ er layer to at least a portion of the foam profile Other embodiments include the step of attachi ng a stiffener to at least one of the foam profile and the co\ er layer In certain of those embodiments, the passing step further includes passing the stiffener through the resin coating station w hich ma;, coat at least a portion of the stiffener with resin In other embodiments of the e aspect, the er la> er inc l udes an edge, at last a portion of w hich is coated w ith the resin , In still other embodi ments, the co\ er la> er includes a coated side and a reverse side, and the reverse cover er side ib disposed proximate to the foam profile In certain of those embodiments, the coated co% er las er si de and

the resin form a bond upon contact. Additional embodiments of the abov e aspect adhere at least a portion of the cover layer to at least a portion of the foam profile SnI l 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 CO N er la} er to a shape corresponding to a shape of the foam profile.

[0021] In s et another aspect, the invention relates to a method of making a ss eatherstπp hav ing a foam profile, a resin coating, and a cov er layer, the method including the steps of providing a foam profile, passing the foam profile through a resin coating station, ss herein at least a portion of the foam profile is coaled ss ith the resin, ss hi le the resin is in a substantial!} liquid state, and applying the cov er las er to at least a portion of the foam profile In certain embodiments of this aspect, the portion of the foam profile to w hich the cov er las er is appl ied is coated with the resin. Additional embodiments of the abov e method include the step of attaching a stiffener to at least one of the foam profile and the cov er lav er, and mav 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 incl ude the step of applying the cos er la> er to the foam profile prior to the passing step In other embodiments the cover layer is applied to the foam profile sv ith at least one roller, w hich mas occur while the resin is in a substantially liquid state. Certain embodiments of any of the abov e aspects mas include a cov er lav er, vs herein the cover lav er forms at least one w and, and or the cos er las er mav be abraded [0022] In other aspects, the inv ention relates to a w eatherstrip made m accordance w ith an) of the abos ^r e-recited methods. In another aspect, the invention relates to a ss eatherstπp hav ing a foam profile, a stiffener, and a cover la> er over the foam profile attached to at least one of the foam profile and the stiffener along longitudinal edges of the cov er layer, so as to decouple at least a portion of the cover Ia) er from the foam profile In another aspect, the

inv ention relates to a system for manufacturing weatherstrip, the system ha\ ing a foam profile source, a stiffener source, a cover lav er source, a resin source, a de\ ice for attaching the stiffener to the foam profile, a dev ice for at least one of apply ing the co\ er layer to at least a portion of the resin and applying the resin to at least a portion of the cover lav er, and a de\ ice for coating w ith resin at least a portion of at least one of the foam profile and the stiffener In stil l another aspect, the ention relates to a method of making a w eatherstrip hav ing a cov er las er and at least one of a foam profile and a stiffener, the method incl uding the steps of providing the cover la> er, pro\ iding at least one of the foam profile and the stiffener. applv ing 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 w elding station, thereby securing at least a portion of the cover layer to the at least one ot the foam profile and the stiffener,

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] A more complete appreciation of the invention in accordance with the depi cted embodiments and manv of the attendant adv antages thereof w ill be readilv obtained b> reference to the following detailed description when considered in connection w ith the accompanv mg drawings, in w hich:

• FIG 1 is a block diagram illustrating the ov erall operation of one embodiment of an apparatus for manufacturing coated w eatherstrip; • FIG 2 is a plan v iew of a die plate in accordance vMth one embodi ment the coated weatherstrip manufacturing apparatus of FlG. 1 ;

• FIG 3 is a cross-sectional v iew illustrating the coating of a substrate using the die plate of FIG 2.

• FIG, 4 illustrates a weatherseal formed in accordance with one embodiment of the coated weatherstrip manufacturing apparatus of FlG. I ;

• FIG, 5 is a plan view of a die plate in accordance with another embodiment of the coated weatherstrip manufacturing apparatus of FIG, 1 ; • FIG, 6 illustrates a glass run channel formed with the die plate of FIG, 5.

• FIG, 7 is a partial block diagram illustrating the operation of another embodiment of a coated weatherstrip manufacturing apparatus;

• FIG, 8 illustrates a weatherseal formed in accordance with the embodiment of the coated weatherstrip manufacturing apparatus of FIG, 7; • FIG, 9 illustrates another weatherseal formed in accordance with another embodiment of the coated weatherstrip manufacturing process;

• 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 FlG , 9;

• FIG, 1 1 is a schematic representation of a manufacturing apparatus in accordance with one embodiment of present invention;

• FIG, 12 is a schematic representation of a manufacturing apparatus in accordance with another embodiment of the present invention;

• FIGS, 13A- 13F are block diagrams of various embodiments of fabric application processes suitable for use in the manufacturing apparatus depicted in FlG, 12; • FIGS, 14 is a schematic end view of one embodiment of the fabric applicator die of FIG,

13E;

• FIGS, 1 5A-1 5C are schematic side views of fabric applicators in accordance with other embodiments of the present invention;

• FIGS, 16A- 16L are schematic sectional view s of v arious embodiments of fabπc-dad foam weatherstrips in accordance with certain embodiments of the present invention.

• FIG 1 7 is a schematic sectional \ ie\v of a fabπc-clad extruded hollow bulb seal in accordance w ith an embodiment of the present invention, • FIGS. 18A- 1 SD are schematic sectional view s of a fabric-clad w eatherstrip manufactured in accordance with alternati\ e embodiments of the present inv ention , and

• FIG. 19 is a schematic sectional view of an embodiment of a fabric-clad foam weatherstrip manufactured utilizing ultrasonic w elding

DETAILED DESCRIPTION [0024] FIG 1 schematically illustrates the ov erall operation of one embodiment of an apparatus for manufacturing coated w eatherstrip The product produced m thi s process is a w eatherseal of the tv pe shown in FIG 4, which includes a foam bod\ or profi le w ith a thin skin or coating and hav ing bonded thereto a stiffener w hich is used to attach the w eatherseal to a structure, such as a door or w indow jamb. The stiffener is supplied from a reel 20 The sti ffener is first heated to approximately 1 20°-240 ³ F . by a hot air blower, for example, in order to slightly soften the stiffener and to facilitate the removal of tw ists 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 w ith the adhesive and skin material in processing steps described below . [0025] 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 adhesiv e is applied to the stiffener. The adhesiv e ma> be applied b> a conv entional hct melt sv stem or other methods. The adhesiv e ma> be chosen to effect secure bonding of the foam to the stiffener. It w ill be recognized by those skil led in the art that the adhesn e uti lized w ill

depend on the materials to be bonded as well as the temperatures the resultant structure experience during subsequent processing steps and in use as a w eatherseal In one embodiment, effective bonding of low density SλNTOPRJENE® foam to a polypropy lene stiffener is achieλ ed with hot melts such as EXTRENfE λDHESIVES® ADT-067 or other amorphous polypropylene based hot melts, or thermoplastic rubber-based pressure sensitiv e hot melts SλNTOPRENE is manufactured by Ad\ anced Elastomer Sy stems. LP EXTREME ADHESIYES ADT-067 is manufactured by Adhesive Engineering & Supply , Inc. The characteristics and properties of S ANTOPRENE are disclosed in U S. Pat Nos 4, 1 30.535 and 4,3 1 1 ,628. the disclosures of which are incorporated by reference herein in their entireties SANTOPR-ENE is a thermoplastic elastomeπc composition including blends of olefin rubber and thermoplastic olefin resin.

[0026] 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 adhesn e has been applied at a point schematical ly indicated at 35 In order to secure an effecth e bond, the foam ma)' advantageously have no longitudinal tension as it is bonded to the stiffener

[0027] The foam-stiffener combination is then pulled through a coating die, such as die 40. w here an outer lay er 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 w ater, a water bath, or forced air. An air w ipe subsequently removes excess water from the weatherseal. if necessary The coated w eatherseal 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 abov e- described operation. Generally, the puller may produce a line speed in ranges from about 10 tc

200 feet per minute to about 50 to 100 feet per minute. In certain embodiments, the line speed for producing the w eatherstrip is about 60-75 feet per minute; m other embodiments, the l ine speed is about 75- 100 feet per minute, Factors such as the surface area of the substrate or portions thereof w hich are to be coated effect the line speed and ma\ be taken into consideration.

[0028] 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 w ith 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 produα [0029] With reference to FIG 2, a die plate 50 of the die 40 is t\ picall \ formed of metal and has a thickness ranging from about 0.5 to 0.75 inches. These dimensions, how ever, w ill N ary 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 approximate^ 0 25 inches As noted with respect to die thickness, this dimension is not critical and ma\ be \ aned in accordance w ith 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 b\ the extruder 42 into the resin channel 55 , Although the resin admitted to the resin channel 55 in the present embodiment is produced b> an extrusion apparatus, this is not a necessai ) requirement. For some materials, the application of sufficient heat will create a melt w hich ma\ be forced into the die under pressure by conv entional pumping techniques. The pressure is approximate!) 100 pounds per square inch (psi) and ma}' v ary between about 50 and 1000 psi depending on the coating process Some polymers, how ev er, 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

[0030] The melted resin admitted to the resin channel 55 \ ia the opening 60 is di\ ided into tw o 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 meteπng gap (described below ) Increasing the screw speed of the extruder 42. for example, increases the pressure w ithin the resin channel 55. As discussed below , the pressure w ithin the resin channel 55 controls the thickness of the coating la% er or skin deposited on the substrate [0031] A die opening 70 is formed with a w all portion 75 having \ arying 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 an\ shape in accordance with the discussion below, As detailed below, the height of the w all portion 75 varies in accordance with the position of the w all portion in the resin channel 55 and the thickness of the outer la\ er or skin desired on the substrate at that point The die plate 50 cooperates w ith a face or scraper plate 90 ing an opening 91 therein corresponding to the die opening 70 and w hich is secured thereto in a manner to enclose the resin channel 55 as shown in FIG 3. The gaps betw een the face plate 90 and the w all portion 75 form a metering gap 92 for the resin. [0032] The pressure w ithin 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 ot pressures within the channel 55. Therefore, in order to ide a layer of uniform thickness to a substrate, the height (or thickness) of the wall portion 75 may be v aried such that the size (or length) of the metering gap 92 is correlated w ith 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 w all 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 w all portion height at point 85 forms a larger metering gap and permits a greater N olume 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 mas be varied by adjusting the length of the land on the top of the w al l portion, as required for particular applications.

[0033] The size of the height of metering gap 92 v aries betw een about 0 00 to 0.2 inches in one embodiment for the door seal The size of the metering gap ma\ \ an depending on the requirements of particular coating operation. The size of the metering gap at \ arious portions of the resin channel may be varied to prov ide a uniformly thick skin or to pro\ ide a skin whose thickness varies depending on position. The ability to pros ide a skin of % an ing 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 easih controlled and ma} cause different portions of the substrate to be coated with different thicknesses.

(0034] An optional ridge 87 illustrated in FIG. 3. is formed on an inner side of the w all portion 75 , The ridge 87 is spaced approximately 0.050 inch below the top of the adj acent wall portion and is approximate!} 0 030 inch w ide 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 w ith the first range of pressures w ithin 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 pre\ ent 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 1 01 , a uniform skin ma\ 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 subsequent!) flo λ S onto the substrate 1 0 1 being pulled through the die opening 70, Thus, a low pressure thin stream of resin flow s into the pocket 97. Although the resin is at high pressure in resin channel 55. the ridge S ⁷ ma\ form a low pressure region or a pocket 97 for applying the resin to the substrate 1 01 . The application of the resin at approximately atmospheric pressure aids in the production of a uniform skin Testing has demonstrated, how ever, that neither the ridge 8 ^" or the pocket 97 are required to produce a high quality uniform coating

[0035] The face plate 90 is secured to the die plate 50 by screw s 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 9S serve to position the substi ate 101 in the die opening and further prev ent the resin from tra% eling back aw as from face or scraper plate 90. The resin coated on to the substrate is doctored b> the face plate 90 made of metal w ith the door seal profile cut therein to produce an outer las er 102 Thus, a loss pressure, thin stream of resin is forced into the pocket 97 from all sides and as it contacts the substrate, it is doctored

[0036] 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 How ever, assuming a constant line speed, the coating of rigid and non-rigid substrates seems to ha% e shghtls 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 meteri ng 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 w ith a rigid substrate and the face plate plays a more important role m determining thickness b\ scraping or doctoring the applied resin In the die configuration of the abo\ e-descπbed 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 relativ ely low pressure. It is important to ensure that sufficient material is supplied to pro\ ide a skin for the rigid portion A flow channel ma\ be cut into the face plate to increase the resin flow at that point In \ arious embodiments, some or all of the resin channel may be formed in the face plate

[0037] Utilizing certain embodiments, it is also possible to coat onl> selected portions of a substrate by providing no metering gap at particular points in resin channel 55 That i s, at particular points, the top of wall portion 75 abuls face plate 90 and no resin flow s though This ma;, be desirable in applications such as w eathcrseals where portions of the seal perform functions adλ ersel) 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 1 1 0 An adhesive layer 1 12 bonds the foam profile 105 to the stiffener 1 10. The stiffener 1 10 includes barbs 1 1 5 , which secure the door seal 100 in a jamb or the like As noted abo\ e. the skm 107 should have a low coefficient of friction in order to facilitate the opening and closing of a door Howe\ er, this low friction skin 107 should not cover the barbs 1 1 5. so that the seal can be effectn ely secured to the door jamb A low friction las er cov ering the barbs 1 1 5 would

inhibit their abilit} 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

[0038] In certain embodiments, the applied resin ma;, also be sufficient!) hot to form a thermal bond w ith those portions of the substrate to be coated in one embodiment, the SANTOPRENE foam and the pol)"propylene stiffener are coated with a non-foamed

S λNTOPRENE-blend skin. The SANTOPRENE blend prefei ably consists of "50 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 follow ing " SANTOPRENE" is a commercial product code which defines certain characteristics of the SANTOPREN E grade. The SANTOPRENE blend is extruded from a single screw extruder The temperature of the melted SANTOPRENE blend should be approximate!} 480° F. to form a thermal bond w ith the stiffener and the foam The SANTOPRENE-blend skin has a relati \ eh low coefficient of friction, is soft and compliant, has good strength and has a good resistance to compression set. The SANTOPRENE-blend skin also achiev es a good thermal bond w ith the SANTOPRENE foam and the pol> prop\ lene stiffener.

[0039] The abo\ e-described method ma> be utilized w ith resins haung a w ide range of \ iscosities 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 v ersions of the above including SANTOPRENE. polyethylene, eth\ lene/methacr} lie acid copoh mer, ethylene 'eth\ 1 acr> late poh mer. linear low density poh ethylene polymers and copoh merizations therew ith, ethylene interpolymer chlorinated polyolefin blends, ionomers (S URLYN E). poh prop) lene and poh propylene copolymers. n> Ion, polyesters, and thermoplastic poh urethane and mixtures thereof, SURLYN is a registered trademark of DuPont. As noted abos e. room temperature

liquid resins such as latex emulsions compounded from silicones, acrylics, polyurethanes. and natural or synthetic rubbers may also be used

[0040] 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 general ls indicated at 140 The die plate 140 includes a resin channel 1 55 formed on one side thereof and an opening 1 60 A die opening 170 is formed with w all portions 1 ⁷ 5 ha\ ing \ ar> ing heights and having a ridge 1 87 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 ha\ ing semi-c> lindπcal foam portions 21 Oa ₁ 2 10b. 2 1 0c adhesi\ ely secured to inner w alls 207, 2OS. 209 respectis ely.

[0041] In order to coat the surfaces of foam portions 210a, 210b. 21 0c w ith an outer !a> er 220. the glass run channel 201 is pulled through the channel of die opening 1 "0 Resin is forced b> pressure in resin channel 155 through metering gaps formed b> w all portions 1 75 and a corresponding face plate (not shown) in a manner similar to that discussed w ith respect to the above described embodiment,

[0042] The methods and apparatus described herein ma) also be utilized to pro\ ide multiple outer layers to a substrate. Thus, with reference to FIG 7, a substrate such as the foam- stiffener combination described above ma\ be pulled through a die 340 ha\ ing a liquid resin supph 345 and be coated with a first outer layer If it w ere desired, for example, to provide strips of a low er friction material over the first outer layer in order to produce a low friction contact surface, the foam-stiffener combination w ith the first outer la> er could be pulled through a second die 350 ha\ ing a liquid resin supply 355. This w ould generate the low friction strip 345 on a w eatherseal 3 10 as illustrated in FIG S For example, the first die may appl\ a skin utilizing the above-referenced the SANTOPRENE blend w hile the second die may appl> a

latex skin as a low friction overcoat. The heat from SANTOPR-ENE cures or dries the latex, Alternatively, the second die may pump a slurry of w ater and micronized polv ethv lene or tetrafiuorethv lane pow der or silicone pow der or other low friction materia) onto the hot SANTOPRENE It will be apparent that this second lav er ma; cover all or am portion of the first la; er in accordance w ith the desired final product. It w ill also be apparent that any numbei of lav ers ma; be prov ided Embodiments of a product utilizing a low friction la> er, and s\ stems and methods of manufacturing same, are described in more detail below .

[0043] Still another embodiment of the method of manufacturing coated w eatherstrip ma; utilize the multiple die arrangement of FIG. 7. A substrate such as the foam-stiffener combination described abo\ e may be pulled through the die 340 and be coated v\ i th a first outer er cov ering onl\ a selected portion thereof. The resultant combination could then be pul led through the die 350 and portions of the substrate not covered b\ the first Ia;, er could be coated w ith a second lav er coextensiv e with the first lav er Thus, as shown in FIG 9, a low friction strip 395 may be provided directly on a selected portion of the substrate w ith the remainder of the coated portions of the substrate cov ered with a las er 3 S5 of different material .

[0044] FIG. 10 illustrates a die plate in accordance w ith another embodiment of the apparatus for manufacturing coated w eatherstrip A die plate 440 may be utilized to pro\ ide a dual extruded skin The die plate 440 includes resin channels 455a and 455 b containing first and second different resins, respectiv ely. for coating a substrate pulled through a die opening 4 ⁷ O. 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 4ό0b The resin in the resin channel 455a is di\ ided into tw o streams bv a die portion 465 The resin channels 455a and 455b arc 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 show n)

" ¹ ^ _

into a low pressure pocket formed by a πdge 487 from where the> are applied to the substrate The embodiment of FIG 10 may be used to produce the w eatherseal shown in FIG 9

[0045] One aspect of the w eatherstrip produced in accordance w ith the described methods is that a less oriented skin is produced, i e., the skin molecules are not aligned to the same degree as the\ would be in. a crosshead evtxusion The low orientation produces a skin which is strong and rubber} The skin has uniform strength in all directions and does not propagate lengthw ise tears. The skin is less oriented since it is not draw n-down onto the substrate as in a t% pica! crosshead die as m other prior an methods and sy stems

[0046] In addition, a high pressure die, because of the high pressures and the resulting flow rates, requires \ er\ careful channeling to ensure that the pressures are balanced The intricate channeling and the requirement of w ithstanding high pressures require machining and generally increase production costs The die used in one embodiment of the described system is utilized in a relatn el) low pressure system which tends to balance its ow n pressures and does not require intricate channeling Low pressure regions in the die of the disclosed apparatus ma\ be easily compensated for reducing the height or thickness of the w all portions Dies of this t\pe are easier to make and are significanth less expensive than con\ entional crosshead dies

[0047] In one example of manufacturing coated weatherstrip. S ANTOPRENE hav ing a durometer reading of 64 was foamed in accordance w ith the method detailed in the aforementioned commonh assigned patents A stiffener of pol\ prop> lene w as bonded to the foam profile as shown in FIG 1. A blend of 750 parts SANTOPRJξNE 221 -64, 250 parts

SANTOPRENE 223-50, 50 pans Ampacet P l OOβl , and SO pans of a color additiv e w as melted in a 1 - 1 4 ^" ' extruder operated at 95 rev olutions per minute and fed into a die of the t\ pe show n in FIGS 2 and 3 w ith the die at 480 ⁰ F The foam-stiffener combination w as pulled through the die at 50 feet per minute and subsequent!) cooled

[0048] In accordance w ith one embodiment of the present ins ention> tear-resistant, loss - fπction, pol> propylene fabπc or other co\ er layer may be combined with the compression set resistance of foam and a coating la> er or skin to provide a product exhibiting desirable sealing and long life using a cost effective production method of appls ing the fabric to the foam substrate. Alternatively a porous fabπc, non-\vo\ en fabric w ith or w ithout a fi lm las er, single las er or laminated fi lm, metal mesh, fabπc or metal cladding, reinforcing film or fabπc . or WΌλ en fabric ma> be utilized as the co\ er layer. The cov er la\ er may be the fabric thermoplastic copolymer sold by Xamax Industries, Iiic , under the trade name FLOLAMS Cos er las ers utilizing a non-w oven pols prop) lene fabric w ith a pols. props lene film or coating applied to one or both sides of the fabπc mas also be utilized Such a non- w o\ en poh propylene composite is sold bs Xamax Industries, Inc , under the designation Q ECM. Thickness of the fabπc cover las er mas 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 las er may s ars from about 1 o&'sq s d to about 2 oz, sq > d or more. depending on the application. In certain embodiments, the fabπc cos er las er is coated w ith a 2 mil polyprops lene film, and has a basis w eight of 1 .25 oz.'sq yd The application of the fabric or cos er las er may be incorporated into the s> stems and methods described abos e regardi ng manufacture of coated foam weatherstrip Additionally, the terms ''fabric las er," ""cos er layer, ^" ''fabric cos er layer." '"cladding," "sheathing," "fabric laminate. ^" ' etc , are used interchangeably herein and throughout this document, and use of one term or another does not in ans ss as l imit the particular type of layer or material that may be utilized in a particular application In certai n embodiments, the coating acts as a tie layer, to permanently bond the fabric las er through combined application of heat and pressure The fabric layer can be util ized to fully or partial is encapsulate the foam core. The fabric may be applied in strips to pros ide losv friction areas,

hinges, reinforced areas, chafe resistant areas, or color match areas in order to impart specific characteristics to the product, The fabric layer mav also be applied directlv 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 pro\ ided b> the fabric l as er The coating layer may be a lower cost material to act primarily as a tie lav er, depending on the application and product exposure to the env ironment The fabric layer mav optionally ha\ e a secondar _e s extruded layer, extruded onto the edges to protect them from catching and lifti ng w ith use, utilizing polyethylene, TPV, TPE, pols prop} lene. 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 L ¹ V resistance, moisture resistance w ater tightness, ultra-low friction coefficients, etc. Additional ly, the fabric las er mas be coated w ith a film or adhesi\ e to improv e bonding properties w ith the coating Alternativ e K . the fabric hv er can be attached to the foam or other portion of the substrate solels bs the secondary Ia; er at solely the edges, or partialis or full} along the cross-sectional extent. Exemplars embodiments of weatherstrip manufactured in accordance w ith the present inv ention are depicted in FIGS 16A- 16L, though other configurations are clearly contemplated and w ithin the scope of the invention. [0049] Various embodiments of the invention are contemplated One embodiment of a process line 750 for manufacturing fabric clad weatherstrip is depicted in FIG 1 1 This figure is described in more detail below, FIG. 12 depicts a clad w eatherstrip manufacturing apparatus 500. letters at v arious points along the process line 502 indicate points sv here the fabric strip mas 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 de\ ice 508 (e g , a hot air blow er 508a or hot plate 508b). The foam profile 5 10 and stiffener 5 12 are bonded or adhered together and drawn through a coating die 5 14 by a puller 5 1 6 The coating die 5 14 ma> be supplied w ith molten resin by a separate extruder 5 1 8 The coated foam profile/fabric 'stiffener combination 520 is then rolled or otherw ise processed for storage, distribution, etc Application of the fabric strip at the various points are described with reference to FIGS. 13A- 1 3 F

[0050] FIG. 13A depicts an embodiment of an apparatus 530 that secures the fabric 532 to the foam profile 5 10 a distance downstream of the extruder 504 after the profile 51 0 has expanded to substantially its final shape The fabric 532 is applied to the profile 5 10 from a fabric roll 534 utilizing a contoured pressure roller 536 in combination w ith a contoured pressure plate 538 or other roller of the appropriate geometry The heat generated b> the new K extruded foam profile 510 may aid in adhering the fabric 532 to the profile 510 Dow nstream of the pressure roller 536, a stiffener (not show n) is applied to the fabric foam combination 542 [0051] FIG 13B depicts another embodiment of an apparatus 550 that secures the fabric 532 to the foam profile 5 1 0 during a supplemental heat stage An opti onal heat plate 50Sb, hot air blow er 50Sa, corona, or other thermal apparatus may be used to heat the extruded or unreeled foam profile 510 to prcλ ide better adhesion of the fabric 532. Similar to the embodiment depicted in FIG 1 3A, a contoured pressure roller 552 is used in combination w ith a support plate 554 or roller of the appropriate geometr\ to adhere the fabric 532 to the profile 510. Alterna ely, the hot plate 50Sb may be used in place of the support plate 554 or roller. Downstream of the pressure roller 552. a stiffener (not shov. n) is applied to the fabric foam combination 542,

[0052] FIG 13C depicts an embodiment of a fabric application apparatus 560 w herein the fabric 532 and stiffener 5 1 2 are applied to the foam profile 5 1 0 substantial!) simultaneously on the process line, Two opposing contoured pressure rollers 562a, 562b may be utilized to apply the two components to the profile 5 10. This application method may be utilized for profiles 5 10 that have a stiffener 512 secured on a side directh or general!)' opposite the fabric 532 The resulting foam profile 'fabric/stiffener combination 564 can then be passed through the coating die,

[0053] FlG 1 3D depicts an embodiment of a fabric application apparatus 570. w herein the fabric 532 is applied to the foam profile dow nstream from the stiffener application Similar to the embodiment depicted in FIG, 13λ. a contoured pressure roller 5 ⁿ 2 is used in combination w ith a support plate 574 or roller of the appropriate geometr) to adhere the fabric 532 to the profile/stiffener combination 576, The resulting foam profi le fabric stiffener combination 564 can then be passed through the coating die

[0054] FIG . 13E depicts another embodiment of a fabric application apparatus 5 S0. w herein a fabric applicator die or plate 582 is utilized upstream of the coating die 514 to appl\ the fabric 532 to the foam profile 'stiffener combination 584 The fabric applicaior plate 582 ma) be secured or bolted 594 to the coating die 5 1 4 ss ith or w ithout a thermal break 586. w hich 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 5S4. Optionally, a guide 590 ma) 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 5 14. w here the exterior la\ er or skin is applied via the resin channel 592. as described w ith regard to the manufacture of coated w eatherstrip. 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 ma> be used in place of the fabric applicator plate 582 are described herein

[0055] FIG 13F depicts another embodiment of a fabric application apparatus 600 w herein the fabric 532 is applied to the coated foam profile 602 dow nstream from the coating die 514 Similar to the embodiments depicted in FIGS 1 3 A. 1 3 B, and 1 3D, a contoured pressure roller 604. is used in combination w ith 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 Ia) er immediate!) dow nstream of the coating die 5 1 4, w hile the coating is still m the molten state The coated foam profile fabric stiffener combination 520 is then rolled or otherw ise processed for storage. distribution, etc

[0056] FIG 14 is an end \ lew of one embodiment of the fabric application plate 582 depicted in FIG 1 3E The plate body 610 defines a tapered, general 1) conical channel 588 how e\ er, different shapes are contemplated, depending on the geometry of the profile 510 and desired finished w eatherstrip product requirements Additionally , a recess 6 14 may be foimed in a low er portion of the plate 582 to accommodate all or a portion of the stiffener 5 12 In the depicted embodiment, a bottom opening 616 of the die 582 retains the foanVstiffener combination 61 2 as the channel 588 tapers from an o\ ersized profile 5 SSa to a point 588b w here the channel 588 is approximately the same size as the toam stiffener combination 61 2 As the fabric 532 follow s the taper of the channel 588, it is gi adually formed until it achie\ es the desired shape and proximity to the profile 5 1 0 at w hich time it may be adhered to the toam profile 5 1 0 The channel 588 is sized to accommodate both the fabric 532 and the foam profi le 5 1 0. w ith sufficient, gradual cun ature to properly form the fabnc 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.

[0057] Additional fixtures and/or guides may be utilized either upstream or dow nstream 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, 1 5A- 15C show se\ eral embodiments of fabric application stations 620a. 620b. 620c for apph ing a fabric 532 to a profile 510 at the entrance of a coating die 514, Additionally , these fabric guides may be used for appK ing a fabric to a profile downstream of the coating die 582. The fabric guide 622a. 622b, 622c ma\ 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 Io 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 receiv e the fabric and orient the fabric to apph it at the proper location on the profile,

(0058) 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 ₅ 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 w hich the fabric 532 can pass The fabric 532 is routed between the armatures 626a and guided by the bar 624a. w hich 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 foamVstiffener combination 576 through the coating die 582. The plate 624b may ha\ e 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.

[0059] FIG 1 5C depicts a fabric guide 622c having multiple rods or bars 624c that allovv the approach angle α of the fabric to the foarrb stiffener combination 576 to be adjusted, as required for a particular application. Additionally, the fabric roll (not show n") may be positioned such that an initial approach angle of the fabric 532 relatn e to the foarrvstiffener combination 576 (i.e., the fabric angle θ) ma} be adjusted as needed to provide sufficient clearance depending on the application, fabric qualities, etc Approach angles α betw een greater than 0 ^D and less than about 90° are contemplated. For foam profiles ha\ ing a general!) flat top surface, the approach angle α ma> be larger than those used for contoured profiles In one embodiment for a round profile, the approach angle α and the fabric angle θ are substantially the same, and in a range of less than about 45°, The guide 622c functions to conform the fabric 532 to the shape of the profile stiffener combination 5 ⁷ ό. Such a configuration allow s the guide to mere!) shape the fabric, w ithout significant!) redirecting the fabric 532 from the fabric angle θ to the approach angle α, as a large deviation betw een those tw o angles increases friction and may cause undesired creasing or breakage of the fabi ic 532 In one embodiment, this angle, α', is less than about 10° from the foamvstiffener combination In other embodiments, the angle α ¹ ma) be less than about 5° This angle ma} be maintained for distances up to and abo\ e 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 se\ eral inches upstream of the coating die

[0060] FIGS 16A-16L schematicallv depict cross-sections of v arious embodiments of fabπc-clad foam weatherstrip 630 manufactured in accordance w ith the present mλ ention. Embodiments of weatherstrip made in accordance with the in\ enhon ma\ include stiffeners and foam profiles of v irtuall) an> configuration For example, generallv linear and T-shaped stiffeners are depicted in FIGS 16A-16L. but other shapes, w ith or without retention barbs are contemplated Similarlv , cross sections of foam profiles ma> be of an) shape, including square, circular, L-shaped, trapezoidal, ov al, triangular, etc. Additionally , hollow foam profiles mas be used, as well as non-foam profiles FIGS 16A-16L are schematic depictions, thus the sizes, thicknesses, etc of the \ arious elements are not to scale Further, it should be understood that the \ arious depicted elements are generally shown spaced apart for claπtv . however, unless otherwise described, the elements are in mating contact

[0061] FIG 16A depicts a w eatherstrip 630 wherein the fabric lav er 632 on!) partial!) co\ ers the coating 634 and the foam profile 636 The coating 634 includes portions 638 that o\ erlap at least a portion of the stiffener 640 to prov ide additional attachment of the profile 636 to the stiffener 640 FIG. 16B depicts a fabric la> er 632 complete!) co\ eπng the exposed foam profile 636 The edges 632a of the fabric 632 are cov ered b) discrete portions 63S of the coating layer 634 to anchor the fabric 632 and prev ents the fabric edges 632a from releasing from the profile 636 FIG. 16C depicts a fabric la> er 632 completel) cov ered b\ the coating 634 of the weatherstrip 630. FIG 16D depicts fabric 632 located solelv on the sides of the w eatherstrip 630, above the coating 634. prov iding reinforcement

[0062] 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 w eatherstrip 630 similar to that depicted in FIG. 16E ₁ 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 abo\ e the coating 632, similar to that depicted in FIG. 16A The fabric 632 can be mechanically treated with an abrasive (e.g , a w ire wheel) to scuff the fabric 632. The scuffed surface 644 of fabπc 632 ma> pro\ ide increased cushioning, sealing thickness, an improved seal against irregular surfaces, and may further reduce friction FIG 16H depicts a w eatherstrip 630 utilizing the coating 634 to hold the fabric 632 against the foam profile 636, w ithout completely surrounding the foam profile 636. The fabric 632 may still be utilized on a portion of the foam profile 636, with or w ithout the use of adhesiv e.

[0063] FIG. 161 depicts an embodiment of weatherstrip 630 hav ing an irregular shape w ith fabric 632 ", 632 " ' in two different locations, The fabric 632' located on the outer top cur\ ature 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 w idth bs the skin 634, or free-floating. FIG. 16J depicts an embodiment of the w eatherstrip 630 utilizing a ribbed or striated fabric 644. which may pro\ ide additional sealing against in egular surfaces, friction resistance, etc. The ribs 644" may- be formed in the fabπc 644: alternativ ely . ribs of low friction coating can be applied to spaced locations on the fabric

[0064] FIG 16K depicts an embodiment of the weatherstrip 630 wherein a pleat 646' is present in the fabπc 646 create a sealing wand 648. Alternate eh or additionally, materials may also be extruded onto the fabπc layer to create sealing w ands or fins FIG 16L depicts another embodiment of the w eatherstrip 630, where the coating ia> er 634 partial 1\ ov erlaps lhe

edges 632a of the fabric 632. In this embodiment, and in other embodiments where the coating does not completely the fabric, the coating layer may overlap the fabric lav er at its edges as desired for a particular application. Manufacturing tolerances ma> dictate the minimum required overlap, z, but o\ erlaps of about 0,03 in, to about 0 06 in are t> pical Larger ov erlaps 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 ov erlap of the fabric is not required. In certain embodiments overlaps of up to about 0 2 in. are utilized

[0065] Other types of seals 660 can benefit from appl ication of a fabric las er, as depicted in FIG 1 ". For example, silicone or rubber profiles 662 (either solid or hol loa) can ha\ e a fabric layer 664 applied thereto, as depicted in FlG 17 The core void 666 of the depicted hollow profile 662, can be pressurized or supported on a mandrel when the fabric las er 664 is applied to provide support, if desired Additionally, the fabric cover las er may be applied to all or part of the outer surface of the bulb and or stiffener, uti lizing mans of the same processes described herein for manufacturing foam ss eatherstrip, modified as needed for hollow extruded bulb applications. The fabric las er may almost entirely surround the profile 662, and may be secured onl> at the stiffener 668. General!} . the barbs 670 in such an embodiment remain exposed in the finished weatherstrip The coating las er 634 can be applied er, under. or solels along the edges of the fabric layer 664

[0066] In instances where the fabric layer is only bonded to the profile at the edges, and/or ss'here the coating layer does not fully encapsulate the foam profile, weatherstrip performance properties can be improved. FIGS. 1 8A- 1 8B depict an example of a weatherstrip 700 made in accordance w ith the present in\ ention The ss eatherstπp 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 lav er 710 co\ ers the profile 706, and is secured only at its edges 712 b\ the coating layer 708. FIG. I SA show s the vs eatherstrip 700 in a neutral or unstressed position When a force F is applied to the top of the weatherstrip 700. as depicted in FIG 1 8B. the w eatherstrip 700 is deformed, This deformation may occur as a result of a w indow or door closing against the weatherstrip 700. As the weatherstrip 700 deforms, the foam profile 706 is compressed (outline 714 show s the shape of the weatherstrip 700 prior to the application of force F). As the foam profile 706 compresses, the fabric Ia) er 710 separates from the profile "06. forming gaps 716 between the profi le 706 and the fabric 7 1 0 In foam profi les, these gaps 7 16 expose an internal surface area of the profile 706 (essential l> along the entire length of the w eatherstrip 700). that _' allow s for improλ ed air mo\ ement in the w eatherstrip 700. enabling faster compression at low er resistance and corresponding!;, faster reco\ en w hen the force F i s remo\ ed. This feature provides for enhanced performance and sealing effects eness In embodiments of the w eatherstrip 700 configured as depicted, the profile 706 ma\ deflect significantly, w ithout corresponding deformation in the coating 70S 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 w ear on the weatherstrip 700 or indi\ idual elements

[0067] FIGS. 18C- 1 8D depict another weatherstrip 700 ^" , having a stiffener 702 ^" w ith a barbed extension 704' produced in accordance with another embodiment of the in\ ention The foam profile 706' is fully coated by the coating la% er "OS ^' with a fabric layer " 1 0 ' on top. As depicted, w eatherstrip 700' is dimensionally similar to w eatherstrip 700 w hen in the neutral position. Application of force F' against the weatherstrip 700 ^' is depicted in FlG 1 8D As the force F' is appl ied, the weatherstrip 700 ' deforms along its length As the w eatherstrip 700 ' deforms, the foam profile 706 ^" is compressed (outline 714 ^' show s the shape of the w eatherstrip 700 ^" prior to the application of force F'). Unlike the w eatherstrip 700 uti lizing 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 70S' , bulges 71 8 can form on the outer surface of the weatherstrip 700" .

[0068] As known to those of ordinary skill in the art, compression load deflection (CLD) curves are important in determining suitability of foam w eatherseals in fenestration applications As depicted, the weatherstrip 700 of FIG. 18B ts pically can be compressed further than the weatherstrip 700' of FIG 1 8D. under a similar load This improved compression load deflection performance is, therefore, highlv desirable in applications such as w indow and door seal applications. Further, compression set and compression force can be reduced, because the foam can compress free of an> surface constraints caused by a continuous surface layer of coating or fabnc. Weatherstrip drag or friction can also be reduced, since the fabric las er can shift or mov e relati\ e to the underlying foam profile. Sealing can also be improved, since the fabric layer can ha\ e a tendenc> to w iden and flatten, w hen the foam profile is compressed. Sealing application that require more robust sealing, how ev er, nonetheless can benefit from the fullv encapsulated and attached foam profile.

[0069] The process of applying fabric to the inside or outside of the skin or coating lav er 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 efficiencv of applv ing sequential components and lav ers of polymeric material to the product Thermal bonding may be used adv antageously in order to join the components together to produce a complex weatherstrip structure in cross sectional profile, but w ith 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

-O -

requirements. The foam profile production process rate is controlled by the conv en or speed, the stiffener rate the first puller speed, and the coated combined product b> 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 alternate e, foam and 'or stiffener components can be pre-e\truded 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,

[0070] Settings for one embodiment of a weatherstrip manufacturing apparatus (such as an embodiment of the apparatus depicted in FIG. 1 1 ) are depicted in Table A, below This exemplary process line utilizes extruders for the foam profile, stiffener u\ hich may be co- extruded w ith 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 w eatherstrip disclosed herein In the Table, the e Feeder and Extruder Speeds are dial settings The screens are utilized in the extrusion process. Dual screen systems are used for \ anous sizes (e.g . 14 openings'in. and 40 openings in.)

Table A: Process Line Settings

[0071] The layout of the stiffener die is generally in-line with the coating, die and hot- melt adhesiv e applicator, with the foam being carried into the path of the stiffener from a π ght- angle approach, Likewise, the direction of resin flow supply ing 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 paral lel with the stiffener extruder with an elongated adaptor w ith an ''S" channel situated therein, allow ing, on the inlet end. a means of attaching the adaptor to the face of the coat extruder exit face plate by mounting screw s set in a circular fashion. In one embodiment, a pipe fitting is attached at the die end of the "S" channel w hich 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, consen ing floor space and allowing a single operator to run the line This also allow s the foam con\ e> or. w hich is required to gradualK cool the foam to nearh ambient surface temperature, to extend paral lel to, but behind, the coat extruder, gi\ ing the operator good visibility and control ON er the foami ng process The offset adaptor plate positions the coating resin extruder aw a> from the location where the fabric is applied, w hether it is at the foam conve\ or, 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

[0072] In certain applications, foam is reeled under predetermined tension and oi ientation, and unw ound from the reel and combined with poK eths lene film uti lizing guidance and tension control methods In these applications, guidance and tension control can be used to more effecth eh feed the release liner film onto the product dow nstream of the coat die Alternate ely, 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 rotan 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 ent damage to the foam products

[0073] Additionally, a preheating or corona treatment stage mas 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 betw een components of weatherstripping or other coated products, Further steps of appl) ing 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 w ell For fabric la> ers that are treated w ith an adhesive coating, a preheating station of the ty pes described ma\ be utilized prior to applying the fabric !a\ er to the foam profile or stiffener, to ensure a satisfactory bond. Alternatively, the heat generated b\ the coating die itself or the extruded foam or stiffener may help secure the fabric, depending on the thermal properties of the adhesh e used

[0074] The shape of the extruded stiffener ma} ¹ also be controlled by utilizing a single brass block w ith the shape of the product cut along the length of the upper surface This block may be fitted into a holder attached to a ¹ S aCUUm apparatus to produce stiffener profiles more precisely than ha\ e previously been achie\ ed A series of slots ma\ 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, B\ controlling the vacuum, the cooling of the molten stiffener may be accelerated while at the same time being supported by the brass block. thereb> creating a superior product shape control process.

[0075] One embodiment of a process line 750 for manufacturing fabric clad weatherstrip is depicted in FlG 1 1 , A foam extruder 752 extrudes the foam profile ^" "54 using w ater as a blow ing agent onto one or more con\ e\ ers 756 w here it obtains its final shape as it cools A stiffener extruder 758 extrudes the stiffener 760. which is cooled in a w ater bath ^" 62. while being pulled b> a puller 764, Alternatively, an integral stiffener barb element ma\ be manufactured utilizing a coextruder, An optional heatmg'dr\ ing station 766 ma} be utilized to treat the extruded stiffener 760, depending on the size or shape of the stiffener (e g , large extrusions ma> require one or more drying stations). The foam 754 and stiffener 760 are joined at a glue table 768. which is fed b> a glue machine 770 This combination foam, stiffener element 772 ma\ be passed through another heating 'drying station 774, if desired

[0076] A fabric spool 776 dispenses fabric 77S along the distance traveled b> the combination foarrb stiffener element 772 The fabric 778 is not attached to the combination foam' stiffener element 772 at the glue table 768, but passes generally abo\ e the table 768 As described with regard to FIG, 15C. a small approach angle α, accordingly . the fabric 778 els near to parallel to the combination foam'stiffener element 7^2 until it reaches the fabric guide 776. After forming to the shape of the combination foanVstiffener element 772. the uncoated

weatherstrip passes through the coating die 778, which is fed by the coating extruder 780 The finished coated w eatherstrip 782 passes through a water bath 784 to cool λn end puller 786 pulls the finished weatherstrip to a reel or cut-up station 790 for final processing

[0077] Fabric clad foam w eatherstrip ma> also be manufactured using ultrasonic welding in lieu of, or in addition to, the resin coating application One such ultrasonic w elding station 800 is depicted in FlG 19 In this embodiment, the foam profile 802 and stiffener 80-4 ha\ e been joined and the fabric co\ er las er 806 applied to the foam profile stiffener combination Instead of or in addition to using the coating die ( _^ depicted in FIG 1 1 for example) to secure the fabric la\ er 806 to the foam profile stiffener combination, one or more ultrasonic w elds are utilized to join the \ aπous components In the depicted embodiment, a foam profile 802 secured to a T-shaped stiffener S04 is passed betw een t ^» o steel w heels 80S that guide the stiffener 804 and hold the CON er lay er 806 in place The w heels 80S also press against the stiffener 804 and co\ er las er S06 The stiffener S04 passes os er one or more ultrasonic horns S l O, w hich form the w eld betw een the components at locations 81 2 Other configurations are possible, depending on w hich ^ eatherscnp elements are w elded, w here the w elds are located, etc Accordingly , an ultrasonic welding station 800 mas entireh replace the coating die station in the process line depicted in FIG 1 1 Alternate eh the fabric las er mas be secured utilizing continuous or intermittent mechanical fastening ss stems ( _^ staples stitching pressure rollers, etc ), thermal fusion, etc Additional components mas be utilized to create a strong bond, for example, a las er of thermall) compatible material mas be applied to faci litate a bond generated thermal fusion After securing the fabric las er w ith ultrasonic ss elding mechanical sy stems, fusion, or other forms of attachment, the w eatherstrip mas either b; finished w ith a complete or partial resin coating, or simph utilized ss ithout ans 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 dow nstream from the alternative attachment station, although certain types of alternative attachment (e.g , mechanical fastening) ma> produce a satisfactory product even if installed dow nstream from the resin coating station.

[0078] The invention has been described in detail in connection w ith the preferred embodiments These embodiments, how ever, are merel> for example only and the inventi on i s not limited thereto It will be appreciated those skilled in the an that other \ aπations and modifications can be easily made w ithin the scope of the in\ ention as defined by the appended claims

[0079] What is claimed is ¹