WO2001094091A1 - In situ gasket moulding - Google Patents

In situ gasket moulding Download PDF

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Publication number
WO2001094091A1
WO2001094091A1 PCT/AU2001/000665 AU0100665W WO0194091A1 WO 2001094091 A1 WO2001094091 A1 WO 2001094091A1 AU 0100665 W AU0100665 W AU 0100665W WO 0194091 A1 WO0194091 A1 WO 0194091A1
Authority
WO
WIPO (PCT)
Prior art keywords
gasket
hollow form
shape
foam
opening
Prior art date
Application number
PCT/AU2001/000665
Other languages
French (fr)
Inventor
Robert William Gilbert
Gary Gordon Leslie Fimeri
Paul Michael Schwarz
Patrick Joseph Mccaffrey
Original Assignee
Schefenacker Vision Systems Australia Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schefenacker Vision Systems Australia Pty Ltd filed Critical Schefenacker Vision Systems Australia Pty Ltd
Priority to EP01937860A priority Critical patent/EP1292438A1/en
Priority to US10/312,540 priority patent/US20030094772A1/en
Priority to JP2002501638A priority patent/JP2003534957A/en
Priority to AU2001263649A priority patent/AU2001263649A1/en
Publication of WO2001094091A1 publication Critical patent/WO2001094091A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R1/00—Optical viewing arrangements; Real-time viewing arrangements for drivers or passengers using optical image capturing systems, e.g. cameras or video systems specially adapted for use in or on vehicles
    • B60R1/02—Rear-view mirror arrangements
    • B60R1/06—Rear-view mirror arrangements mounted on vehicle exterior
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B29C44/16—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining shaped by the expansion of the material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S248/00—Supports
    • Y10S248/90—Movable or disengageable on impact or overload

Definitions

  • This invention relates to a method of forming a gasket on a hollow article during the process of filling the article with foam.
  • Mirror heads are generally pivotally connected to supporting brackets which are in turn attached to motor vehicle bodies.
  • the brackets are normally moulded components and are attached via threaded fasteners. They have a gasket or thin rubber sealing strip placed between the bracket and the body of the vehicle. This gasket forms a weather-proof seal between the vehicle and the bracket.
  • gaskets are either pre-cut to the required shape or are injection moulded from rubber. They are either glued to the bracket or held in place during assembly.
  • This specification describes an improved method of providing either a gasket or seal for a component that is attached to another article.
  • the invention could be suited to applications in other areas so the invention as described herein is not necessarily restricted to the application of mirror heads and attachment brackets.
  • the invention is a method of forming a gasket over an opening of a hollow form comprising: placing an unformed gasket over a mould surface having a shape in relief being the shape to which said gasket is to be formed; placing said hollow form onto said mould so that said gasket is held between said opening of said hollow form and said mould surface, and locating expanding foam material within said hollow form so that said foam pushes against said gasket to form it to the shape of said mould surface said shape being retained upon setting of said foam.
  • the pressure exerted by the foam while the hollow form is held against the mould is sufficient to cause the gasket material to deform to the required shape as defined by the mould.
  • the hollow form is held against the mould as the foam cures so that when the product is released from the mould, the gasket retains the shape of the mould.
  • This process has the advantage of moulding the gasket to the required shape while at the same time using the foam to glue the gasket to the hollow form.
  • the gasket also stops foam leaking out during the filling process.
  • the process avoids the need of forming the foam directly against a mould surface which would require use of a mould release agent.
  • the avoidance of using any mould release agents is important, as residues of these agents may migrate to surfaces that require painting. This is not possible if the surface is contaminated with mould release agent.
  • Figures 1 to 6 show the production steps for foam filling of a mirror head incorporating a gasket over an opening on a mirror mounting bracket.
  • the process starts with a hollow form or article 10 having an opening 11.
  • the article 10 is to be filled with expanding foam and it is also to have a gasket 12 formed across the opening 11.
  • the gasket 12 is to be formed during the moulding process into the required shape. This is achieved using a mould 13 that has the required shape 14 in relief on the surface of the mould.
  • the process comprises cutting or moulding the gasket 12 to the required shape. It is then placed against the mould 13 and held in place by the article 10 as shown in Figure 4.
  • Foam 15 is then injected into the cavity of the article 10. The foam 15 expands and applies pressure to the gasket 12 so that the gasket 12 forms the shape defined by the mould 13. This is shown in Figure 5.
  • the required amount of pre-mixed foam may be placed within the article 10 just prior to it being placed against the gasket 12 and mould 13.
  • the article 10 can be removed from the mould 13. The foam will adhere the gasket 12 to the article 10 and also maintain the required shape.
  • this aspect of the invention provides a greatly simplified means of manufacturing an article with a pre-fitted gasket rather than having to assemble the article with the gasket at a later stage. Also it meets the requirements of sealing an article with an opening with is to be filled with foam. A combination of these features produces a useful and unique result.
  • Such components include electronic sensors such as proximity sensors to determine if the vehicle mirror is close to an obstruction, sensors that sense external temperature and humidity, and sensors incorporated with the car security system such as motion detectors.
  • Other various electronic equipment may be incorporated into the mirror mounting brackets such as lights used to light the area around the vehicle, or lights that may be controlled from within the vehicle that enable the light to be moved so as to provide directional lighting.
  • Speakers and microphones used to communicate to people external of the vehicle may also be incorporated as well as antennas for various apparatus such as mobile phones, GPS devices and other radio communication devices.
  • transmitters may be incorporated into the mounting bracket which are used for controlling external objects such as garage doors or providing radio transmissions which may be used, for example, to track or locate the vehicle.
  • Other electronic devices such as automatic toll payment systems or remote transaction systems may be incorporated into the mounting bracket to enable electronic registration of various toll payments.
  • Cameras may also be incorporated into the mounting bracket which are both forward and rearward looking which are designed to continuously digital images and to store those images either on command or as a result of an accident.
  • Motion sensors can be used to determine the occurrence of an accident so that images before and after the event are stored.

Landscapes

  • Engineering & Computer Science (AREA)
  • Multimedia (AREA)
  • Mechanical Engineering (AREA)
  • Rear-View Mirror Devices That Are Mounted On The Exterior Of The Vehicle (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Gasket Seals (AREA)

Abstract

The invention is a method for forming a gasket over an opening of a hollow form. The method comprises placing an unformed gasket (12) over a mould surface (14) having a shape in relief that is the shape to which the gasket (12) is to be formed. A hollow form (10) is placed onto the mould (13) so that the gasket (12) is held between the opening (11) of the hollow form (10) and the mould surface (14). Expanding foam (15) is located within the hollow form (10) so that the foam (15), as it expands, pushes against the gasket (12) to form it to the shape of the mould surface (14). This shape is retained upon setting of the foam. The invention greatly simplifies the manufacturing process of a hollow form (10) fitted with a gasket (12).

Description

IN SITU GASKET MOULDING
This invention relates to a method of forming a gasket on a hollow article during the process of filling the article with foam.
This application describes improvement to the external mirror assembly and method of manufacture described in the applicant's earlier International Patent Application PCT/ AU00/00054. The disclosure contained in that specification is included by reference to this specification. This specification should be reviewed in conjunction with the disclosure contained in the above application.
BACKGROUND
Mirror heads are generally pivotally connected to supporting brackets which are in turn attached to motor vehicle bodies. The brackets are normally moulded components and are attached via threaded fasteners. They have a gasket or thin rubber sealing strip placed between the bracket and the body of the vehicle. This gasket forms a weather-proof seal between the vehicle and the bracket.
Traditionally, such gaskets are either pre-cut to the required shape or are injection moulded from rubber. They are either glued to the bracket or held in place during assembly.
This specification describes an improved method of providing either a gasket or seal for a component that is attached to another article. The invention could be suited to applications in other areas so the invention as described herein is not necessarily restricted to the application of mirror heads and attachment brackets.
SUMMARY OF THE INVENTION
In its broadest form, the invention is a method of forming a gasket over an opening of a hollow form comprising: placing an unformed gasket over a mould surface having a shape in relief being the shape to which said gasket is to be formed; placing said hollow form onto said mould so that said gasket is held between said opening of said hollow form and said mould surface, and locating expanding foam material within said hollow form so that said foam pushes against said gasket to form it to the shape of said mould surface said shape being retained upon setting of said foam.
The pressure exerted by the foam while the hollow form is held against the mould is sufficient to cause the gasket material to deform to the required shape as defined by the mould. The hollow form is held against the mould as the foam cures so that when the product is released from the mould, the gasket retains the shape of the mould.
This process has the advantage of moulding the gasket to the required shape while at the same time using the foam to glue the gasket to the hollow form. The gasket also stops foam leaking out during the filling process. Also, the process avoids the need of forming the foam directly against a mould surface which would require use of a mould release agent. The avoidance of using any mould release agents is important, as residues of these agents may migrate to surfaces that require painting. This is not possible if the surface is contaminated with mould release agent.
Although this invention has numerous applications, a particular application described in this specification will be in relation to its use with foam filling of hollow forms such as mirror heads or mirror mounting brackets. Gaskets on such hollow forms perform a number of functions. For instance they are used to form a seal between the component and attachment point of the vehicle (to provide weather proofing), to provide a better fit to the vehicle and/ or to improve the appearance of the joint. In order to fully understand the invention as described above, a preferred embodiment will now be described. However, it should be realised that the scope of the embodiments described do not restrict the invention to the precise detail of the embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
Figures 1 to 6 show the production steps for foam filling of a mirror head incorporating a gasket over an opening on a mirror mounting bracket.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As seen in Figure 1, the process starts with a hollow form or article 10 having an opening 11. The article 10 is to be filled with expanding foam and it is also to have a gasket 12 formed across the opening 11. The gasket 12 is to be formed during the moulding process into the required shape. This is achieved using a mould 13 that has the required shape 14 in relief on the surface of the mould. The process comprises cutting or moulding the gasket 12 to the required shape. It is then placed against the mould 13 and held in place by the article 10 as shown in Figure 4. Foam 15 is then injected into the cavity of the article 10. The foam 15 expands and applies pressure to the gasket 12 so that the gasket 12 forms the shape defined by the mould 13. This is shown in Figure 5.
In addition to injecting the foam 15, the required amount of pre-mixed foam may be placed within the article 10 just prior to it being placed against the gasket 12 and mould 13.
After the foam 15 is set, the article 10 can be removed from the mould 13. The foam will adhere the gasket 12 to the article 10 and also maintain the required shape.
The article 10 is then ready to fit directly to either a motor vehicle body or some other fitting. Clearly, this aspect of the invention provides a greatly simplified means of manufacturing an article with a pre-fitted gasket rather than having to assemble the article with the gasket at a later stage. Also it meets the requirements of sealing an article with an opening with is to be filled with foam. A combination of these features produces a useful and unique result.
Australian Patent No. 639105 titled "Spigot Type Break- Away Mirror" and International Application No. AU00/ 00068 titled "Pivot With A Detent" describe pivot mechanisms that may be incorporated between a mirror mounting bracket and a mirror head. The disclosure of both of these specifications is incorporated in its entirety herewith. The pivot mechanisms disclosed in both of these specifications that may be used with the mounting bracket described in this invention.
Australian Patent Application No. 68997/98 titled "A mirror operating Mechanism" and International Application No. AU00/ 00009 titled "A mirror rotation mechanism" described electric power fold mechanisms which move a mirror head from its normal in use position to a parked position where the mirror head is rotated towards the body of the vehicle. Both of these inventions could be used with the mounting bracket described in this invention and the disclosure of both of these specifications is incorporated in their entirety within this specification.
International Patent Application No. AU00/ 00413 titled "method of producing a plastic moulded part including a film covering" discloses a method of forming a moulding component comprising an outer thin film component with an adhered moulded shell. This invention could be used to mould the hollow form component subject of this invention and the disclosure of this application is incorporated herewith in its entirety. International Patent Application No. AU00/ 00815 titled "Load support for a wing mirror" describes a method of supporting a mirror head on a mounting bracket. This support could be incorporated on the mirror mounting bracket subject of this invention and the disclosure of this application is incorporated in its entirety herewith.
It would also be possible to incorporate other components with the mirror mounting bracket. Such components include electronic sensors such as proximity sensors to determine if the vehicle mirror is close to an obstruction, sensors that sense external temperature and humidity, and sensors incorporated with the car security system such as motion detectors. Other various electronic equipment may be incorporated into the mirror mounting brackets such as lights used to light the area around the vehicle, or lights that may be controlled from within the vehicle that enable the light to be moved so as to provide directional lighting. Speakers and microphones used to communicate to people external of the vehicle may also be incorporated as well as antennas for various apparatus such as mobile phones, GPS devices and other radio communication devices. In addition, transmitters may be incorporated into the mounting bracket which are used for controlling external objects such as garage doors or providing radio transmissions which may be used, for example, to track or locate the vehicle. Other electronic devices such as automatic toll payment systems or remote transaction systems may be incorporated into the mounting bracket to enable electronic registration of various toll payments.
Cameras may also be incorporated into the mounting bracket which are both forward and rearward looking which are designed to continuously digital images and to store those images either on command or as a result of an accident. Motion sensors can be used to determine the occurrence of an accident so that images before and after the event are stored.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:
1. A method of forming a gasket over an opening of a hollow form comprising: placing an unformed gasket over a mould surface having a shape in relief being the shape to which said gasket is to be formed; placing said hollow form onto said mould so that said gasket is held between said opening of said hollow form and said mould surface, and locating expanding foam material within said hollow form so that said foam pushes against said gasket to form it to the shape of said mould surface said shape being retained upon setting of said foam.
2. A method according to claim 1 wherein said gasket sheet is pre-trimmed to correspond to the shape of said opening and the thickness of the wall of said hollow form.
3. A method according to claim 1 wherein said hollow form comprises a vehicle mirror bracket.
4. A formed gasket attached to a hollow form comprising: a hollow form having an opening, and a gasket located over said opening that is formed to a required shape by holding said gasket between a mould and said hollow form, where said mould surface has a shaped surface, being the shape to which said gasket is to be formed, and locating expanding foam material within said hollow form so that said foam pushes against said gasket to form it to the shape of said mould surface, said shape being retained upon setting of said foam.
5. A formed gasket according to claim 4 wherein said gasket is shaped as required prior to fixing to said hollow form.
6. A formed gasket according to claim 5 wherein said gasket has a peripheral edge that extends past the edge of said opening.
7. A formed gasket according to claim 5 wherein said gasket has a peripheral ridge that locates within and around the edge of said opening.
8. A gasket according to claim 4 wherein said hollow form comprises a bracket for a vehicle mirror.
9. A method of forming a gasket substantially as herein described with reference to the accompanying drawings.
10. A formed gasket substantially as herein described with reference to the accompanying drawings.
PCT/AU2001/000665 2000-06-05 2001-06-05 In situ gasket moulding WO2001094091A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP01937860A EP1292438A1 (en) 2000-06-05 2001-06-05 In situ gasket moulding
US10/312,540 US20030094772A1 (en) 2000-06-05 2001-06-05 In situ gasket moulding
JP2002501638A JP2003534957A (en) 2000-06-05 2001-06-05 Gasket and method of forming gasket
AU2001263649A AU2001263649A1 (en) 2000-06-05 2001-06-05 In situ gasket moulding

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPQ7949 2000-06-05
AUPQ7949A AUPQ794900A0 (en) 2000-06-05 2000-06-05 Improved external vehicle mirror and method for manufacture

Publications (1)

Publication Number Publication Date
WO2001094091A1 true WO2001094091A1 (en) 2001-12-13

Family

ID=3822021

Family Applications (2)

Application Number Title Priority Date Filing Date
PCT/AU2001/000664 WO2001094154A1 (en) 2000-06-05 2001-06-05 Improved external vehicle mirror and method for manufacture
PCT/AU2001/000665 WO2001094091A1 (en) 2000-06-05 2001-06-05 In situ gasket moulding

Family Applications Before (1)

Application Number Title Priority Date Filing Date
PCT/AU2001/000664 WO2001094154A1 (en) 2000-06-05 2001-06-05 Improved external vehicle mirror and method for manufacture

Country Status (5)

Country Link
US (2) US6896378B2 (en)
EP (2) EP1296851A1 (en)
JP (2) JP2003535747A (en)
AU (3) AUPQ794900A0 (en)
WO (2) WO2001094154A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2399778A1 (en) * 2010-06-28 2011-12-28 SMR Patents S.à.r.l. Mirror base covering

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4961171B2 (en) * 2006-06-22 2012-06-27 株式会社ミツバ Vehicle door mirror
US20080262466A1 (en) * 2007-04-19 2008-10-23 Steve Smith Storage container

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JPS58208025A (en) * 1982-05-27 1983-12-03 Sanyo Electric Co Ltd Manufacture of heat-insulating door
US4681725A (en) * 1983-10-21 1987-07-21 Kabushiki Kaisha Swallow Ski Injection skis and their process of manufacture
US5328648A (en) * 1991-08-14 1994-07-12 Foam Enterprises, Inc. Method of using a composite joint infill system
US6030560A (en) * 1997-09-08 2000-02-29 International Cushioned Products, Inc. Method for making a cushioned article

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JPS58208025A (en) * 1982-05-27 1983-12-03 Sanyo Electric Co Ltd Manufacture of heat-insulating door
US4681725A (en) * 1983-10-21 1987-07-21 Kabushiki Kaisha Swallow Ski Injection skis and their process of manufacture
US5328648A (en) * 1991-08-14 1994-07-12 Foam Enterprises, Inc. Method of using a composite joint infill system
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Cited By (3)

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Publication number Priority date Publication date Assignee Title
EP2399778A1 (en) * 2010-06-28 2011-12-28 SMR Patents S.à.r.l. Mirror base covering
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US8919973B2 (en) 2010-06-28 2014-12-30 Smr Patents S.A.R.L. Mirror base cover

Also Published As

Publication number Publication date
EP1296851A1 (en) 2003-04-02
JP2003534957A (en) 2003-11-25
JP2003535747A (en) 2003-12-02
US6896378B2 (en) 2005-05-24
AUPQ794900A0 (en) 2000-06-29
EP1292438A1 (en) 2003-03-19
AU2001263649A1 (en) 2001-12-17
US20030128446A1 (en) 2003-07-10
AU2001263648A1 (en) 2001-12-17
WO2001094154A1 (en) 2001-12-13
US20030094772A1 (en) 2003-05-22

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