This is a division of copending, commonly assigned Canadian Patent Applicat$on Serial No~ 466,774 filed October 31, 1984.
The invention relates generally ~o molded window gaskets and to the reaction injection molding of such articles from a multi-conscituent material in a mold cavity. More particularly~ the invention relates to equipment for reaction injection molding of ~uch articles, wherein the elastomeric urethane window gaskets are lntegrally molded and securely bonded onto a window panel of glass or other transparent material and include living hinge members incorporated therein. Reference i9 made to the related copendlng Canad:lan appllcations, SerLal No.
448,329 filed February 27, 1984 entitled "Molded Window Gasket Assembly And Apparatus And Method For Making Same", and Serial No. 468,021 filed November 16, 1984 and entitled "Molded Window Gasket Assembly And Apparatus And Method For Making And Bondlng Same", both of whlch are assigned to the same assignee as the present invention.
It has been known in the past to fabricate articles 9uch as modular vehicular window gasketsj having hinge members or portions therein, from materials such as polyvinylchloride (PVC) using conventional compression or injection molding techniques. Some of such window gaskets have been in~ection molded directly onto the window panel, which is made of glass or other substantially transparent material. The window and gasket assemblies have then been installed in a vehicle or other window frame w1th adhesives LCM:jc
- 2 - ~ ~5~
and/or with integrally molded fastener protrusions, as disclosed~ for example, in United States Patent No.
4,072,340, and with hinge members therein as disclosed in United States Patent No~ ~,1391234. It has been found, however, that window panel brealcage has been unacceptably high in such prior processes because of the high pressures required in the in~ection molding prccesses and because of the hardness and rigidity of the mold structures involved.
Additionally, because of the t~pes of materials previously used in molding the gaskets, such as rubber or polyvinylchloride (PVC), it has been found that proper adhesion of such gaskets to metal body panels and to glass window panels has been dlEEicult to attain, thereby resulting in water leaks, wind noise, and other related problems9 as well as requiring the use of mechanical fasteners to secure the assemblies to the body panels.
In accordance with the present invention, improved apparatuses for reaction injection molding articles such as vehicular window gasket assemblies are provided in order to o~ercome the above-discussed disadvantages. Such apparatus allows window gasket assemblies to be reaction injection molded from multi-constituen~ materials, such as urethane, for example, and to be molded at relatively low pressures and securel~
bonded directly ontG the glass or other transparent window panels.
According to the invention of the parent application, such gasket assemblies include at least one LCM:jc _ 3 _ ~ ~5~
movable gasket member and a flexible living hinge web integrally molded therewith in a one-piece structureO The window panel assembly can then be movably mounted ~n a window opening ln a body panel and secured thereto. In one embodiment, the gasket assembly also includes at least one integrally molded fixed gasket member with the hinge web interconnectably extending therebetween. The fixed gasket melnber i9 ~dapted to be bonded and securetl directly to the vehicle body with adhesives without the need for mechanical fastener devices, thereby simplifying the installation process and making it better suited for robotic or other automated equLpment. Because of the incorporation of the flexible living hinge web integrally molded into the gasket assembly such ease of installation i9 also attainable in window arrangements such as rear quarter windows and Eolding convertible top windows, for example, wherein at least one window panel must be pi~otally movable relative to the vehicle body. All or a portion of the preferably urethane gasket can also be coated with a plgmented decorative material in the mold cavity if desired.
The gasket assembly may also be fabricated with a lower cros~-sectional profile9 thereby providing for an advantageous, aerodynamically smooth fit between the window assembly and the body panel. Such lower profile also re~uires less offset or other forming of the body panel area surrounding the window opening9 thus slmplifying the body panel fabrication and increasing the design flexibility for such body panels. Also because in at least LCM:Jc some embodiments of the invention the gasket and window assembly is preferably bonded and secured to the body panel substantially continuously around the window opening periphery, the localized stress concentration9 callsed by spaced, discrete mechanical fasteners are substantially avoided and the bonding and securing forces are more evenly distributed. Such modular window structure, with its strong and preferably continuousl peripheral bond allows the window panel to effectively contribute to the structural integrity of the installation, and also to allow for a reduction in window panel thickness and weight.
The strong and secure bond between the preferably urethane gasket member and the preferably glass window panel is achieved by a novel method whereby the bonding occurs simultaneously with the molding process. Generally speaking the preferred bonding method includes the steps of applying a primer material, by spraying or wiping9 to at least the peripheral portions of the window panel, allowing the primer to air dry for a relatively short period of time, and inserting at least the peripheral portions into the mold cavity. A flowable urethane, or urethane-containing, multi-constituent ma-terial is then injected or otherwise introduced into the mold cavity where the gasket member is allowed to at least partially cure.
The invention of this application may be characterized as providing a reaction in~ection molding system for molding a window gasket assembly from a mul~i-constituent material in a mold cavity, the system LCM:jc - 4a - ~Z5~
comprising a source of the multi-constituent material in an intermixed pressurlzed flowable s~ate, and mold apparatus including a first mold member and a second mold member mutually engageable with one another and defining the ~old cavity therebetween9 a first por$ion oE the mold cavity being adapted to receive a portion of at least one substantially transparent window panel inserted therein prior to the introduction of the material into the mold cavity in order to mold a movable portion of the window gasket assembly in place on an edge portion of the window panel within the mold cavity, a second portion of the mold cavity being adapted to mold a fixed portion of the window gasket assembly, and a third portion of the mol~ cav:ity being adapted to mold a living hinge web portion of the window gasket assembly in a one-piece integrally-molded relationship with the fixed and movable gasket members, the living hinge web portion interconnectably extending between the fixed and movable gasket members.
In a preferred embodiment of the present invention, an aftermixer apparatus for use ln a reaction in~ection molding system includes a mixing body having at least one common inlet passagewar for receiving a multi-consti~uent material (preferably urethane) in a pressuri~ed flowable state. The apparatus includes a number of mixlng passageways adapted to receive the material from the common inlet passageway and separate it into a corresponding number of material flow streams. A common mixing cavity in fluid communication with the mixing passageway3 reunites LCM:jc ~25~
- 4b -the separated flow streams and conveys the material into a - gating device for introduction into the mold cavity~
Adjustment means is provided for selectively altering the size of the common mixing cavity and the size of its inlets in order to selectively alter the back-pressure exerted on the material flowing therethrough. Such adjustment feature allows for the optimizatlon of the back-pressure and thus the intermixing of the constituents of the material for a given flow rate and inlet pressure thereof. Preferably, the mixing passageways each extend along a generally serpentine path including at least one bight portion adapted to cause the material flowing therethrough to substantially reverse its direction of flow in order to increase turbulence and enhance the mixing of the material constituents.
At least a portion of ~he preferred mold cavity of the reaction injection molding s~stem includes one or more elongated elastomeric members positioned generally adjacent the peripheral edge of the mold cavity for supportingly enga8ing the mold members and the window panel. The flexible elongated elastomeric members are preferably seated in grooves in one or the other of the mold members and are further adapted to substantially minimize or prevent flashing of the gasket material out of the mold cavity and also serve to accommodate variatlons in the shape oE the window panels.
Additional objects~ advantages and features of the present LCM:jc ~erlti~ will becOE~ a~arent frc~ ~ follc~ cription ~nd ~ed dailr5, ~Lken ~1 C~ljl~CtiC~I with the ac~c~Lr~ing dl:aWill98.
Figure 1 i~ an eleva'ci¢.~ ~ew cf ane preferred ga~ket and wind~
panel ~ 5e~;bly ins~lled in a vehicle boay panel ~nd having a movâble w~w F!nel hirP~ly and pivotally m~ble relative to a fixed wir~
;E~nel aa:ording ~ ~e pre6ent iventicn.
~ isure ;~ i6 a c:ross-~ectiona~ ~ taken alc~g line 2-2 o~ ~i~2re .
F~re 3 i8 al~ elevatio3~a~ v~ew cf arl lte3:~te ~ ula W~CW
panel asse.~ly ~imilar ~co that o~ Figure 1, bu~ having only a movabl~
win~7 psnel~ ' Figure 4 1~ a cross-~ctiorlal v~ew taken along line 4-4 ~ Fi~ure
Pigure 5 is a ~rtial perspective ~iew ~ t~e re~r wir.da~ of a cQ~n7ertible ~?r i~l~;tratin~ still anvther allterrate ~dii~nt ~ the present in~entiQn.
Fi ~_c 6 is a sc~lemati.c per~tive vie~ tic~ ~f a Etold aE~arahzs for ml~lding the w~n~ gasket a~se~ly of Fi~ure 1.
Figure 7 is a pQrtial cros~6ec4.ional view generally t~en a~
lir~e 7-7 o~ Figure 6, but wi~h ~e windo~r panels in place ard~ e m~ld a~a.~ cl~ed.
~ igur~a 8 is a sche~Jatic diagram illustrating a reaction ~ld~ng ~ys~ or fabricating and bo~dins tcgethe~ 'Jhe c2sket and w nd3 ~Lne~ asseEbly o~ Figure 1.
Figure 3 1~ ~ per~pectlve view o~ an aftermixer and gating a~3r~tus ~or a re~ction injecti~ ~olding apparatus in accordance ~it~ ~e F~eSent in~entio~.
Figure 10 i~ ~ cro6s-~ectional view ~ken alo.lg line lQ-10 ck Fi3ure ~.
In Figures 1 'chrough 10~ e~emDlary embodim~rlt~ of ~e present irw~i~ are ~llustraLed for t~e re3cticn iniectiorl D~ldir~ an3 bc~
in~gral~-molded v~ ~ar wir~ pa~el gasket a~;~blie~ v~ng rle~cible living hinges integrally molded therein, c~nto their assc~i2ted glass ar o~er albstantialiy tr~ent wi~ E~nelsO ~e skilled ~ t~e art w~
readily rec~nize frcm the follc~wing di~cusEion, h~ever~ ~hat ~e ~rinciple~ ~ lthe ~nventian are ~lly a~?licable to react~on in~ ectica~
m~lding a~ ~2di~ 6)f ~tems othOE than v~culæ windc~ ~ket~, ~5 we~l as being applicable to aE~aratus offaer than the reaction injection ~l~
E~yst~ shown in the dra*~ings.
1~ Fi sure 1 ~nd 2 an e~:~lary ~lar v~ic~ar w~n~7 æsembl~
10 generall~ ludes at lea~t c~ substantially transparelat movable windcF~
p~nel 15, at le2st ~ ~bs~an~ially transparOElt fixed win~ nel 16, and a ~in~ gasket asse~ly 78. A6 ~-lustrat~d in ~e d~wings, t~e ~
p~el~ 15 and 16 and l:he ga6ket a~ ly 18 are ~ to ~e ~alir~
dispo~ i;~ a win~? o~ing ~n a venide bc~ panel ~ or t~e like, wi~
at ~east a fixed psr~cion of the gas5ce'c Pssembly 18 bQnded an~ se~ured direc~ly to a recessed portiorl 14 . o~ the perip~eral are ~ the v~cle ~y s~ro~mding ~e wind~ ~ Wit}l an adhesive ma~r~al lOo ~'lE;~
t~e need 15 elimin2ted for mechanical fasteners protruding '~.~ough 2pertures in the bo~ or e~bedded in t~e ~ ket ~terial the need Cor 8UGll fasteners, t~e cros~sec~ior~l profile of the gc~s~e~
a&fiembly 18 may be m~nimized $n order to provl' de a ~moo~h selzti~e~
uno~trl;~ive fl~ with the vehicle body panel 12~ ~he~e~ redu~clnc7 aero~Lic drag ~ the vehicle. Al&o~ se ~e g2sket ~d ~
a~ly is ~c~red a~d ~ed ~;ubstanti~lly cQnt~ zly aro~d at l~st ~
6~s~2nt~al p~r'iQrl of ~he perip~ery of ~e fiacecl ~r~ pan~l 16~ e winds~ el 15 ef~ectively ~e5 pQrt ~ .e bo~ ~ruc~uce ~nd L5 n~t ~ubjecLed to the locali~ed ~'cress cor~centrations c~u~ed by discrete m~arlical faE;teners. Ihu~ ~t leas' ffle wis~7 Eanel 16 c~ ~ ~rmer an~
li~hter in wei~ht than those prev ously u~ed. If dir~; ~din~
~e bo~ panel 12 and the window panel 16 i~ al~io desired, the w~nacu ~asket asse~ly 18 may o~onally ~e fo~d with a G~nel-~ped ~en~ng 24 exter~ding therethrough ~ or~er to all~7 a ~itable adhesi~e ~o ~ ~e window panel 16 directly to the recessed portio~ 14. Such s~ptiQn c~annel-~ped o~ing 24 nay c~sist of eiff~er a ~ingle ~g e2~tend~
con~ousl~ t~ro~ghout ~e er~tire window gaske~ as5~mbly 18, or a ~eries ~ discrete ~el-shaped c~ngs at &paced ~ at~ o.~ thro~ the wind~ ga~et ass~mbly.
As will ~ecome apparen'c from the discussion ~elcwr ~he wi;ldoS~
ga~ke~ assernbly 18, which is preferably composed o~ urethane or a ~re~ar~tai~r~ material, ~y ~1 so c~tionally ~nclu~ a coat~ng ~
pigmented material either on its entire exteriGr ~urfzce, or orl a predetermir~d portion t:hereof, as ~ ;trated }~y referer~:e mmL~ral 2~.
Such CQating of pi~mented ma~eriR~ e ~F~lied to ~he windaw ga~ket ~ss~ly 18 ~ur~ t:he moldi~ proce~3 ~ order to p~ovide a ~ecora~ve s~ipe on its exterior surfaoe or to color ~he wmd~ ~sket ~r i n order to c~leTent the color s~h~e ~ the vehicle.
As ~hown in the dr~wing~, the exemplary qasket a~E~iy 18 illustrated in Fi~ures 1 znd 2 ~ncludes a ~ble gasket i~ær 23 s~re d arld bonded ~o at leas~ a por~c n of ~e periphera~ ~ge a~ ~.e sn~rable w~r~ panel 15 ar.d a fi~ed ga~ket m~er 27 ~red ana b~3cc~
at lea~ a port~ of t~e perip~eral edge ar~2 29 ~ ~he ~i~ced windc~ p.ar.~l 16. A ~lexible livirlg hinge we~ 35 :~nter~ctably extena~ be~e~ ~.
~va~le ~nd fixe~ sket ~rs 23 ~ Z7, respectiYeiy, and i~ 3~'~ral3.~
mol~. in a o~ne~piec~ st:ructure there~-ithq ~e hlnge ~e~ 35 f~ctic~Ls to hir~e~y znd pivo~ally at~ach ~e ~r~ble ~sket ~ber 23 aL~ t:~e m~ble win~ow panel 15 to the body panel 12 for opening and clo~ng ~i~ot~1 ~v~nt a~ irsdica,ed ~y rrc~ 37.
It ~ould be noted thai al~;sugn both the ~7able ~nd fixed ~ske~
member~ 23 ~nd 27 are shc1wn in the various figures herPin a~ be~r.g inte~rally molded and bonaed substantially continuously ~rollnd ~3ubstantially t:~e entire Derip~eral e~ge area~ o~ ~eir ,espeoti~e W~J
panel~; 15 an2 16, at le2s'c t~e ~able w~ndcw Ee;ael 15 ~ay z~ternat_~ely have it~ ga~ket member 23 integrally molded and bonded only along t~e ~ort~ the e~e Area 25 that i~ generally adjacent t~he living hinge w~
3~. ~n ~uch an alternate ~ t, ~he remainder cf the edge are~ 25 would be bare ~nd wculd sealingly abut or engage a ~aling ~ember ~ ~he peripheral area o~ the body panel 12 ~urroun ~ ~ the wina~ oEe~ng ~en ~n ~t~ clo~ed position.
Figures 3 and 4 illustrate an e~emplary al~ernate modular ~hicular wlndow asse~ly lOa accor ~ to the presen~ ~nv~n~i ~n~ ~in~w ass~mbly lOa i 8imilar to wind~w assembl~ t9~ cf Figures 1 and 2~ kut has ~ly a 8 ~gle windbw p9~1 hingedly and pivotally diD-posed in ~he ~icle ~ nel 120 The s~me re~erence n~meral~ are used for ~e c~rresp~ n~
elememn~s ln the ~arious esbol~nts ~hG~n in the dr2wings for E~-F~es of iilus~rating 80me e~mpl~s of the ma.~y applic2tions or the ~_esen~
. ~ike the wind~w assembly 10 of Figures 1 and 2~ ~e windG~
as~ ~ ly lOa of Fi~u.es 3 and 4 generally includes a ~Lb~.antial~y transps~nt mrv~ble w~n~cw pa~Rl lS and a windcw ~2seket ~ssY~biy 1~. ~he ~asket a~se3bly 18 ~ncludes a m~va~le gaske~ ~e~b~r 23 bond~d ~d ~ecured to 2t le3st a Forti~ cf the EeriEheral eoge area 2~ of ~he ~Vzbl5 WLn~
--S--p~nel 15 ~nd a fixe~3 ~sket m~er ~7 ~cured and ~ed directly to t:he r~ces ed porti~n 14 ¢f the perip~eral ~ or the ~'y E~nel L~ ~rr~ns lthe w~naow opening wi~h an sdhesive material 200 ThuE;~ the need i~
elimir)ated iEor ~Gh2nic21 faster~rs protrudin3 'ch:cough aperb~re~ ~n the ~y or ~ ~ the gasket material.
A flexible living hinge w~b 37 interconn~ctably ect~Ls ~e~e~.
~e ~ovable and :E,xed g~ske~c member~ 23 and ~7, re pectivelyt in Fisures 3 and 4 and i integrally molde~ in ~ on~piece ~trl20ture therewith. ~e h~nge we~ 37 flmctians to hin~edly ~nd pivotally at~ach ~e ~vable y~Lsket ~er 23 ~nd the ~le wind~ Eenel 15 to t~e bo~ el 12 for ~ir~ and closi~g pi~otal a~ i~icated ~ arrcw 371~
Still another example of the maIly varied applications of t.l~.e present ~e.~tion i5 the modular vehicular windc~ ass~bly lOb i~ ~rated ~n Figure 5. Winda7 ass~b.l~ lOb is a folaable rear wiru~a~ afise;~bly ~r ~he~ a ~ft or h~xd ~c~Nertible tcp ~ and generally includes at l~st: a p~ir c~ ~e wiz~7 panel~ 15 and a win~ gaE:ket as~ly 1~
~he Wi;l~ ~nels 15 has a m~vable g~sket ~r 23 ~zed and b~d 'co ~t ~eas~ a portion of their respective periphera~ edge areas 2~;o ~;le m~ le g26ke~ ~Km~er~ 23 are interc~nnectec alcn~ g~ner~lly adj2cent ~i~es by a ~lexible li~ ng hinge web 35, which is integrally ~olded in a on~-~ie~e ~tructure therewith. ~he hinge web 35 ~unctions ,~ allcw ~e Rx~le g2sket me~bers 23 ~nd the movable windc~ panels 15 ~o h~g~dly ~d pivoælly m~Ye rel~tive to one another, as ~ndicated by the 2~`GW 37t ~s ~ e convert~ble top 11 i~ raised or lowered. ~he sides of the gss~et asse~bly 1~ g~nerall~ aajac~t the tc? 11 are preferably ~ e~ ar~ ~e~u~
directly to the top ~ self, ~r directly to a ~ui~able frame or reinforcing m~mDer therecn, with ~n adhesive material wi~hcu~ ~b~ n~d ~.
mechani~al fas ener~ ~s discu~.sed above $n connect~on w~th o~er embodi~ents of the invent on~ It may b~ d~sira~le in ~i~ Q. ~t~ex 3Q~
lic~ti~s to mold ~nd bor~u uret.hane gzsket ~er~, ~nterconr~c~d ~ an ~tegral liv~ hinse we~, only to adjacellt e~ges ~ 2~,~cent win~ ne~s ~ithcut including such gas~et me;l~ers ~ ~e r~i~nq periEheral e~es o the wind~7 panelfi~, The window ~asket member 18 i5 preferably molded from a ~nilti-constituen~ material, ~uch as the preferred li~uid ~ ~ st.tuent ~aterial for exæmple, m a fiuitable r6ac~ion injectlon ~lding ~parat~s ~UGh as the ~ld ~pparatus 46 ~ch~ma~icall~ illustrated in Fisures 6 a~d 7~
~or eY~3~nle. Su ~ urethane ~ate~ial mey ~e compo&ed, for e~a~ler ~ a p~lyol resin constituent, an i~ocyanate cons~it~entt and a ca~aly~t~
EXa~ples of co~merGialy-available polyol re~ins are man~a~tur~d by qhe D~wn ~hemical Cc~sany under ~he tradem~rk VCR~NQL and by Tbxaco Chem~cal C~mpany under the trademark I~ANOL ~F-6503. ~xamples of commercial isocyanates are pro~uced by Ihe UE~ohn Cbmpany under the ~radema~k ISC~
143Lr ISO~IE 181, ISO~ATE 191 and I5D~ 2409 and al80 ~y Xk~hy Chemical C~rpora~ion under the trademarks MCNCUR PF and MO~DUR CD. hn e~ample o~ a suitable catalyst for ~uch urethane ma,er~al i~ n~lket2d by ~ o ~lemi~
C~sany un2er the trademark WrTOO ~ ~Lr2B.
As illustrated ~chem~t~cally ~y the reaction injec~i~n ~ ng fi~8~en 3~ ~n Figure 8~ the ccnstituent6 of the winaow gasket materqal are in~ec~ed ~rom two or more consti~ue~t ~ources 3~ ~nd 34 in'o a hi~hrpressure mi~ing apparatus 36 by way of ~e respe~t~ve ~e ering deY.icc-s 38 ~nd 40. The ccnstituents of the ~akerial are mixed in ~he kighr~ressure ins apparatus 36 at pressures in the range ~f ap~rox~a~ely ~'J00 ~8. ~ Og. to approxim~tely 30Q0 p.s.iOg. and are ccnv~yed to ~n ~'enmi~:e~
and gating aE~aratus 42. AS discussed belcw, ~he a~.ermixer and ga~g a~paratus ~2 ~urther mi~es the cQnstituents of the ga~ket ~er.a~ ~nd re~uces ~ts pressure to a r~nqe of approximate.ly 3a p.S.~
appro~im~tely 1~0 p~.i.g., and preferably approximatel~ 50 ~.s~iDg~, --1~
~efore ~tr~cLny the ~terial ~nto ~ v~y 4~ cf a m~ld ~ar~s Prior to ~he injecticn of ~e ~ ti-~;t.L~F~rlt gasket m~terial into ~e mold apparatus ~, the mold caYi~ 44 ~S preferably s:~ated with ar~ of a r~r of kn~n mold rele2se ~ge.~t~ ypic~ly c~ist or lc~elting point waxes or silicc~ o , for exa~le. ~rcial e~?les ~ ld rele~se agen~ are produced lt~ Cc~t~r ~cal Ca;~y under l~e traa~ark ~RAXO 1711, Exm II, ~ULEASE 125, LI~T and ~IC~ EFE, ~y Freka~e lnc. Ia~de~ ~e tca~rks E~Oæ 34, 3~RE~q~ 3~, FRE'~E 31j, and ~O~S 31Elt ~2d ~ Park Chemical C~2~ ~er the trad~k :E~C7~,.
The volatile mDld release ager~t is ~hen allo~ed to at l~a~ E~'~i~lly g ~
off of ~he ~o~d appar2tu5 46 which i~ typically at a t~m~erature in ~he range o~ a~roxIm2tely llOF to approximately lbOF.
I~ desired, ~ll of the mold cavity s~lrface, or a predetermin~d Fortion thereof, may be c~ated wlth a pigmented material 80 ~ha~ the pigmented material will be transferr~d in ~he ~old to the desired ~urfa~e ~r Eurfaces or the ga~ket ase~bly 18 ~or cther ~lded ar~icle) ~ur~g the rea~ti~n injec~- o~ molding process. An example ~ ~uch pigmen~ed $~teri~1 ~oating is menufactured ~y Sherwin Williams Cb~pany under ~he tra~e~æ k PC&PXE. A~ter ~he pigmen~e~ material co3tins has ~een all~w~d '.o ~l~sh of~, ~he window p~nel 16 ~glass or other transparent m~erial~ ~ Fcsitioned ~n the mold, ahhesive means i8 applied as de~cribed beiow, ~r.d the mo7d ~e~ers 48 and 50 of the ~old ap~Qratus 46 are clo&~d, ~bs~nt'ally ~n mu~ual engagement with one another. me cons.ituen.s of ~he gaskct terial are lniected into the ~y~.e~, moxed ~nd ~n~roduced into ~he m~'~
cavi~.y 44 as described above, and the windcw panel ur panel~ witk the window asket asse~bly 18 in~Jegrally ~lded thereon ~5 th~n re~ove~.
As ~ kn~n to thos2 ~killæ in the ~e~cticn ~r~e~-.ic~ ~ld~l~
artJ the ~nter~.~ed constibuents c ~he m~lding ~aterial under~G a ra~id _,~,_ ~2~
2nd highly excthe~c re~ction in the mold ~vit~y and are ~rox~ ~te~ 7Ut, ~ red within a very ~hort ~ime, ~ erally les~ ~.an ~ne to ~;ix ~nu.~s, depenæing s~n ~che czt~lyst OE~Dl~ed. ~ter s~ch ti~e, the molded ~rt-cle ~y ~e r~wved fr~n the molding appara'cus ar~ lowed to ool ~ t t3Dperatures.
As illustrated in Figure 7, at le~st c:ne, and p~eerEbly b¢th~
~e mold ~ers 48 3~ 50 ~nclude an elc~gated elAsto~ric ~ad ~e~ 56 c~?res~ly ~atecl within a correspondi~ sroave 580 ~he ~r~ves 5~ are p~siti~ed generally adjacerlt tl~e perip~eral e~ges o~ the a;old ~avi~ ~4 fiO
ff~at ~:he eJast~eric m~5 56 cc:~re~;si~ly engage ~nd ~ l~ly ~;~rt either the ~ite mold mesr~er or the wirK3~7 panel or par~s ar.d also 8ub~J~antially pre~ent or min~i~e flashin~ of ~he mold~g ma~er~a~ ~t ~rcm ~e mold cavi~y 44. ~en the ~old a~arat~ B ~ the el~Et~ i~
~s 56 prèferably protrude slishtly frc~ their associated ~;rooves 58 so t}Lat the :Ec~rce requi.red to hol~ the mold merrbers 48 and S0 t~ge~her i~ a ~ling e3~g~ent i8 ~iubstan'cially re~ced fr~ ~he force that wo;21a ~e ne~es~ary if the mold n~ ers were required t~ be forced ~ to direc'.
~ lt?Ct With Cne allotl~er. Simil~rly, a 8ignifiC~Ul'Cly redu~d ~essure i~
es~erted on ~e windc~ panel or p~nels and c~s~uent~ e f ~ y or ~reakage c~ ~e windaw E~nels i5 fiu~st2ntially ~ed or el~ted.
&t:h re~ction in ~he force r~ired to hold ~he mold me~r~ tGge~2er i~
al50 ~ignificant~y le~s tha~-l that r~uirea in e:~nventîor~ c~Dpr~siQ~. and injecticla mol~ processefi~ ~dditionally, the elasta~Deric ~e S 56 ~e s~ffic~en~ly flex ble to all~ ~or minor var~a~ions in ~he sha~ nd ~n.aar of the win~i panel or E~ s and there~ alingly i~c' ate ~he mold cavi~y 44 rec2rdle5s of SUG'l minor windcw ~nel var~atic~sO
Rs ment oned ab~ve, win~;w gasket ~sse~ly 18, wbi~ is pre~ra~lv urethane, i~ securely b~ded to ~e prefe~ably g~2~;;= w~ panel e p~ne~s ~ring 'che molalng process. Prior to ~e in~ec~crl Gr ot~ lC.it~
o the c~rlstituen~:s o the gasket ~terial into t'~e D~ld recesses o~ c~ity 44, the windc~ s~nel br E~els, or ~t le~st the ~p~ro~riate por ~i~ns o .
i:heir periF~Ieral ~ge are~ re de~ned to remwe gr~e, rele2se ~gen~s, or o~her residue or debris. Such cleaning i~ preferably done with an a~kal~ne wash. If, hGwever, the glass w~7 panel or pEIr~15 ~e a1r~L~
relati~ely clean and free o:E release ~ents, a ~olven'c ~ thylene ~lor~deO for ~r~le, i8 ~lied.
~ ext a silane-containin~ materlal ~ app:lied, ~t lea~ to the peripheral edge ar~ portic~s ~d all~ed ~:o fla~ of ~ ~cr a per~ c~ o~
ap,Dr~xi~tely ten ~ to ~roximately thirty ~ecor~sO ~s ~s ~n~ to 1:h~e skilled ln the art, tlLe exact ti~re dep~ds ~n ~actor~ h the mold temperature and the particular ~te;ial u~ed, for ea:~mple~ q~he peripheral edge asea porti~ns are therl wiped to prevent the gla6~, or other tra~enL material, .ram do~d~g.
Prior to ~rting the window E~nel ~r panels irlto the s~old ~
~4, a prLmer m~terial 4~ is applied ~y wiping or sprayir~g to at leas. ~ne ~;ide o~ the peripheral edge area portio~s. A preferred e~ le of ~e primer ~a.erial 45 is BETP~ L glass and metal pr~mer e~3S.2i, as m ~ufa ~ ured ~ ex ~ ~ cal Cor ~ ratiorl, Special~y C~ ~ .cals na~:Lsi¢~.
"B~5~3hL" iB a regis.ered ~ademark of Es.sex ~cal t~r~ratic~
p~r 4~ is air~ried ~or a~?ro~i~tely t~o minutes to a~ro~reLtel~ r~
~utesO ~Ehe ~sket ~aterial coslstituents are t~en in~ected or in~cdu~d ~s~to ~e m~ld ~avi~y 44, which mlst be ~e with~ ~3?prox~1y 33 ~u~es af er ~he pr~me, i8 ~lied. q he gaske~ asse~bly 18 is ~en ~la~d as ~scr~d above, a~.d a ~ng a~hesive ~d intermolecu~ar ~d ~s ashieved.
It fiho~d be noted ~l3at alth~gh the primer ~ r~y alternately ~?li~d to c~ or more of the ~5ite ~;ides and/or ed~e o~ ~e ~erir~.eral e~ge are~ ~ort~ons~ ~n actua~ly-constr~cted prototypefi ~f the m~dular wind~ a~e~biy, the sasket asse~bl~es 18 have ~een mold~d with ~he p~iG~r . -~3-~5 &~ Rnly ~ si~3e of t!le per,~eral e3ge ~ poLt.L~`.'.~s of S:he W~5 ~anels a~ have ~ m to e.vhibit ~n extr~eiy ~trong ~ ~cu~e ~
~us ~uch single-sided a~plication ~ the ~r~r 45 i s preferred ~n order lto prese~e materials and to ~ze the h~lling cf t~e wind~ n~, ~here~y minim~ ng the potential Ior breakage and waste.
Figu-es 9 ~nd 10 illustrate ~n lmproved afte~xer ~d gating ~ara~s 42, generallv i~cluding an after~ er ~Lc~k or ~ 6~
gatis~g ~ock or b~ 6fi ~psition ir one or th other o~ the mold ~er~ 48 or ~0 for fur~er mixing the cons~ituent:; o~ the ga~ket ~a~eria (preferably uret.~ne) and admitting th~ materi21 to i~e ~',d ca~i~y 440 ~ e af termi~er bo~ 6 4 ~nclude~ at least one c~on inlet passag~qay 68 for receîving the ~asket material fr~n ~2e hig~pressure ~ing aE~paratus 36 at a predeter~ined flaq rate and pressure. ~ie ~ske~
~aterial ~cws fflrou~ the isllet pæssageway 68 into at least a pair or cur~ilinear m:i~ing passageway~ 7~ ~nd 74 where it is separated into a corresponding number of flcw ~treams. Such ~eparation increase~ the tur~ul ence of ~he gasket s~aterial flG~ and ~c~crdingly enhances ~e intermixi~2g of its cca~stituents. q~e mi~g pasç~gew~s 72 and 74 inslude B di~i~er wall 76 t~erein, w~ich form a genera~ly ~erp~tine ~ e ~i~in~ ag~ays.. Such serpentine path includes at le~t one b~ght p~rtion 78 in the mixing passageway ~2 ~nd a F:;m~ 1 ar bi~ht portion 82 :~
l~e mixing passageway 74. Such bigh1- portio;ss c~u~e the gasket material to substantially reverse its ~irection of flcw, as indicated b~ ~Le :E~
arrawE; B4 and 86, respectively, in o~der to incr~ase the turbl21~nce of e~c~}
3 g~ket m~terial flcw ~ ms 2nd er~ance the int~r~ing Qf ~.e c03~st~tu~rlts therein~
~ nce t~e gasket ma~rial fl~s thro!ugh t~e mi~;~ p~sag~ys 72 and 74, ~t en~..s a corresFo~ding n~rær of res~ti~7e inlet ~2g5 ~38 and ~0 of at least o~ ing ~v~ 2. ~e ~low ~r~ fr~ ~he , ~g~
mixing }?assag~ays are reurited in the ~Euxing cavit:y 92, which agai n ~everses the ~lcw directions of the fl~w streams, increases thei~
turhulence, and enhances the intermi~cing of the gasket material c~nsti~ent~;. The reunited ~nd intermixed ~cet Iaaterial frc~n ~e mi:c~ng cavity is ~ecei~ y ~e ir~l~t p~agew~ ~4 in the gat~ ~r~ wherein it i~ conveyed through a diverging fan~ate passageway 96 'co ~he mold c~vi~y 44.
~ e ~te~er b~y 64 pre~erably ~c}u~es ~ E~te~d or of~set pGr~iC¢l 102 adap~ed to slidingly e~gage a prefer~ly correspanding 8t:ep~
~f~et portion 104 ~ t~e ~atinq b~ 66, f~U~h ff~at ffle fter~2r ~
64 and the s~a~ ~y 66 m~y be ~3lidably and adju~ t~ward or fra~ os~e snother ~s ~ndicatea ~ t~2e arrc4~s 106 an~3 1080 q~.e s3ti~
~6 allio includes an integrally-~om~ed tongue porticn 110 in whicn ~:he ~a~ing inlet p~sagewa~ g4 i5 ~ormed. ~e tcngue portion 110 i~ ~liZably rec:eived ~n a ~lot .112 in . ~e ~fter~;cer body 64 ~or ~lid~ble and ad3usta2~1e movement ~herein a~ the aftermixer and gating bodies are a2justab1~ moved ai; descri~ed ab~e. I~e end portion 114 o~ l~he ~e p~r~ 110 d~ines t~ie exit portion of the mia~ing c~vity ~ ~ch $.~t selec~ive n~v~ent of t~e tan~le portic~ 1~0 ir~ e slot 11~ ~l~s t~
sizes or the mixing ~avi~ !32 e~ad it8 inlet openis2~s 88 an~ 9D ~o be ~electively altered as the ~te~er ~d gati-~ ~die~ are ~ectiY~ ai~
adjustably moved. I'hu5 the sizes of the mix~ns cavit~y ~nd its inlet ~gs ~ay ~e &electively an~ adjus~ably increa~2d as the a~termixer and gating ~ies are moved apart ~r~ e another, ~d cor;esponainsls!~ 6uch ~iz~s ~ay ~e ~electively and ~djus~bly ~crea~ed as the af~e~m~xer u~a ~at:ing bodies are m~ved todard ~e ~nother. Ln o.der ~ f;ll the ~oc~ie~
gap ~ ffle ?ot 112 in l:he a~termixer ~y 64 arter tl~e ~.ermi~ er ~y .~l5 been a~ fi~ably moved ~qay from the ga~ing ~o~ 66 7 one or ~cre ~hiTa ~ers 120 ale remov~l~ inser'c2bl2 ir.to the ~lol: adjacent ~e erx3 portion .~
~5--114 of the t3ngue llO.
~ he aft ~ er kxx~y fi4 is preferably provided with o~e or ~re elongated ~ ~s 124 therethrc~ch for receiving a ~hreaded $ast~ner 12a ex~ending there~hrough. 5he threaded fastener is aaa~ted to thre~bly engage a threaded aperture 128 ~n the gating ~ody 66 and ~erves as a locking n~ns ~or ~ixing a Ereselected p~sition of the S~ ue ~rticn llO
in the El~t 112~ Preferably, ~he aftermixer k~x~y 64 is ~lso pro~idea with countersuonk ~rtions 130 for allowing the head ~ rtion~ 132 o~ t~e fastener~ 126 in a ~ecessed relationsh~p with the Eurface 134 or the afterILLxer ~x~y 64.
5Ehe aibove-described ~elective ~dju~ ~ e~nts ~o the size of the na ~ ca~ity 92 and its inlet ~slings 34 and 95 allcw for the ~elect~ve ~ teration o the back-pressure exerted by '~he aftermixer and ~atin9 aE~aratus 42 on the ~asket m~terial flowing therethro~ . 5uch altera~i3n fflere~y allow~ ~or the ~el~,tive ~timizat~on of ~e ~te~ of i:~e c~n~tituents of the ga6ket material for a predetermuned ~15w r2te and p~es Æ e c~ ~he material fro~ the his~.-pressure mi~n~ a~?ara~u~ ~6 ~lor~m fiche~atically in ~igure 8. By ~uch adjus~ments, there~orel tb.e user ~f ~he reactiQn ~njection m~}ding ~y5~e~ ~ay ~fine-bune~ the proces~ t~ 3chie~-e optimum i~termixing and reaction of the constituents of the molding ~eterial as well as achi~ving sreater control G~er ~he p¢esEure at wh_ch ~he ~lding material ifi introduced inLo the mold C~Yity.
. ~he foreyoi~g discussion discloses ~nd describes eY.em~12ry e=bcdi=ents o~ ~he pres~t invention. One ~killed in ~he art w~ll r~adily reo~ze ~ f~h disc~;sion t~t va~ ; ~ges~ ti~as ~r~
~ar~at~ons may be made there~n w~thout deFarti~g f;o~ ~le s~irit ar.d Ec~e