Classifications

• • E—FIXED CONSTRUCTIONS
  • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
  • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
  • E06B7/00—Special arrangements or measures in connection with doors or windows
  • E06B7/16—Sealing arrangements on wings or parts co-operating with the wings
  • E06B7/22—Sealing arrangements on wings or parts co-operating with the wings by means of elastic edgings, e.g. elastic rubber tubes; by means of resilient edgings, e.g. felt or plush strips, resilient metal strips

Definitions

• the present invention relates to improved pile weatherstripping. More generally, the invention relates to articles which are made by ultrasonic welding yam to plastic strips or strands. Such welded articles include weatherstripping, brushes, and other articles having tuffs of yarn or pile attached to a backing strip or strand.
• the invention includes methods and apparatus for making these articles.
• the invention improves weatherstripping and methods of making weatherstripping described in U.S. Patent No. 4,302,494, issued November 24, 1981 to Robert C. Horton.
• Pile weatherstripping which is manufactured in accordance with the Horton and Johnson Patents uses a plastic backing strip, one side of which is formed into a channel by plowing and upsetting the material from that side into a pair of flanges by a plowing tool.
• the channel has a base against which loops of strands of yarn are captured and ultrasonically welded to create the weatherstrip.
• the quality of the weatherstrip depends upon the strength and uniformity of the weld section which connects the yam to the backing strip. It is the principal object of this invention to provide improved articles, especially weatherstripping, having yam segments ultrasonically welded to a backing strip in the base of a channel formed of material upset from the backing strip, where the weld is consistently of high quality and where the welding may be carried on at higher line speeds (the speed at which the weatherstrip travels past the welding head during the manufacture of the pile weatherstrip); this line speed being higher than in the case of the weatherstrip manufactured heretofore, and particularly manufactured in accordance with the Horton and Johnson Patents.
• the invention enables fabrication of the flanges which guide and capture the yarn, in the course of manufacture of the weatherstripping, so that no significant stress fracturing occurs in the backing (the base of the channel between the flanges) where it is welded to the pile.
• the absence of stress in the base of the channel enables the flanges to direct the ultrasonic energy for welding, and uses the welding energy more effectively and efficiently.
• the flange guides are upset from the outside of the channel rather than from the inside as is the case in the Horton and Johnson Patents.
• the walls of the flanges are vertical and located, preferably centrally, between the edges of the backing.
• the area at the base of the channel (the width of the channel) maybe of substantially constant and uniform in size and compatible with the bottoms of the loops of the yam so as to form flanges which serve as an ultrasonic energy beam director for efficient and effective utilization of the ultrasonic energy to weld the backing to the pile.
• Another object of the invention is to facilitate installation of the pile weatherstripping in a T-slot in window and door frames so that the pile is easily inserted either by rolling the backing into the throat of the T-slot or by insertion in the end of the T-slot.
• the weatherstrip and T-slot are sometimes staked, such as described, for example, in U.S. Patent No. 5,979,036, issued November 9, 1999, or the frictional engagement of the backing strip against the walls of the T-slot is enlianced as by means of series of nubbins to restrict movement of the weatherstripping within the T-slot, such as described, for example, in Johnson, U.S. Patent No. 5,438,802, issued August 8, 1995.
• the invention also enables the backing to be formed into arcuate, particularly convex or concave, shapes, and even undulating or wave shaped longitudinally along the weatherstrip, so as to form an interference fit when inserted in the T-slot which restricts the movement of the weatherstrip and enhance the seal.
• the ease of insertion and formation into arcuate or undulating shape is facilitated by the reduced section or notch outside the channel and adjacent to the outsides of the flanges.
• the notch increases the flexibility of the backing strip along its width. The backing flexes for insertion into the T-slot.
• the reduced section in the notch also facilitates cold forming of the backing strip into convex or concave or even undulating shapes so as to enhance the interference fit between the weathertstripping and the interior walls of the T-slot, thereby creating a tight fit restricting the movement of the weatherstripping in the T-slot with respect to the frame of the door or window and promoting a tight air infiltration seal in the frame of the door or window.
• the base of the channel maybe provided with a textured surface, preferably with a knurling tube disposed downstream with respect to the movement of the weatherstrip during formation of the flanges.
• the separation between the knurling and cutting tools is desirably sufficient to prevent imparting any strain in the material of the weatherstripping in the channel.
• pile weatherstripping of the present invention has a pile of yarn segments which are attached to a flexible plastic backing strip by ultrasonic welding of the pile thereto. Loops of the yarn are captured in a channel on one side of the backing strip. This channel is formed by extracting flanges from the backing strip by a cutting tool having a pair of chiseled cutting surfaces tapering inwardly and spaced from each other.
• the backing strip is preferably wound on a capstan in a plurality of turns so as to feed the strip past the cutting tool which extends radially toward the periphery of the capstan and into cutting engagement with the backing strip.
• the cutting tool leaves notches along the channel on the outside of the flanges.
• the base of the channel is unaffected by the cutting tool and thus presents a stress-free surface at which the yarn is welded.
• the weld section, connecting the loops of yam to the backing strip, is consistent throughout the length and cross-section of the weatherstrip even when the welding is carried out at high speeds.
• the notches improve the bending flexibility of the backing strip so as to facilitate insertion of the weatherstrip into a T-slot of a window or door frame which is to be sealed using the weatherstrip.
• the backing strip may be permanently set to fomi a convex or concave cross-section, the edges of which engage an interior wall of the T-slot to frictionally capture the backing and the weatherstripping in the T-slot with the pile projecting therefrom.
• FIG. 1 is a plan view, schematically illustrating apparatus for forming a backing strip in the manufacture of pile weatherstripping;
• FIG. 2 is a front view of the apparatus shown in FIG. 1 ;
• FIG. 3 is a cross-sectional view of the backing strip as it enters the apparatus shown in FIGS, l and 2;
• FIG. 4 is a cross-sectional view of the backing strip after the flanges are upset and cold formed by the cutting tool in the apparatus shown in FIGS. 1 and 2;
• FIG. 5 is a cross-sectional view of the backing strip after formation of a knurled textured surface at the base of the channel between the flanges by means of a knurling tool in the apparatus shown in FIGS. 1 and 2;
• FIG. 6 is a cross-sectional view of the finished pile weatherstripping after welding of the looped strands of yarn in the base of the channel and showing the ultrasonically formed weld section;
• FIG. 7 is a fragmentary end view illustrating the cutting tool in process of upsetting the backing strip from a side thereof, thereby cold forming the backing strip into flanges defining a channel, the inside walls of the flanges being straight and upright;
• FIG. 8 is a perspective view of the cutting tool which forms the flanges and the channel in the backing strip;
• FIG. 9 is a sectional view of weatherstrip disposed in a T-slot in frame of a window or door which is sealed by the weatherstrip, the backing strip being cold formed into a concave shape to provide an interference fit of the weatherstrip in the T-slot;
• FIG. 10 is a view similar to FIG. 9 with the backing strip cold formed into convex shape
• FIGS. 11A and 1 IB are respectively a sectional view of a weatherstrip having an undulating or wavy shape backing strip disposed in the T-slot, and a fragmentary perspective view thereof.
• FIGS. 1 and 2 a backing strip 1 of thermoplastic material, preferably polypropylene.
• This backing strip has a generally rectangular configuration as shown in FIG. 3 and may typically be of the order of 1/4 inch long and 1/32 inch high.
• the cross-sectional size of the backing strip depends upon the size of the pile to be fabricated with the weatherstrip.
• the backing strip is unwound from a roll (not shown) and guided around a guide wheel or pulley 12 to a capstan wheel 9.
• This wheel 9 has a flange 9a against which the backing strip 1 is referenced and held by a backing strip support guide 7 which is moveable in the direction indicated by the arrows 7a.
• the backing strip makes a plurality of turns, two turns being illustrated, around the periphery of the capstan wheel 9.
• the backing strip leaves the wheel after the second turn and after the formation of the flanges 15 and channel 16 therein.
• the base of the channel 16 may be left pristine and smooth with flanges 15 extracted from the top side of the backing strip and notches 17 adjacent to the flanges and between the flanges and the outer edges of the strip (see FIG. 4 at 24).
• the base of the channel 16 may be textured as shown at 18 in FIG. 5.
• the backing strip with the textured channel base is illustrated at 26 in FIG. 5. Since the backing strip may have the alternative shapes as shown in FIGS.
• both reference numerals 24 and 26 are used to designate the backing strip leaving the capstan wheel 9.
• a dancer mechanism 10 with a pulley around which the backing strip is guided is disposed at the exit end of the capstan wheel 9.
• the amount of tension in the departing backing strip is controlled by means of a weight which is movable in the direction indicated by the arrows 1 la on the arm of the dancer mechanism.
• the capstan wheel 9 is driven from a shaft 8 through a one-way clutch 28 which enables the capstan wheel to be freely rotated in a clockwise direction indicated by the arrow 9a.
• the motor and drive for the shaft 8 is not shown to simplify the illustration.
• a cutting tool 2 and a knurling tool 3 are supported in a block 6 mounted on the frame of the backing strip forming apparatus, illustrated schematically at 6a.
• the cutting tool 2 is movable along a radius of the capstan wheel 9 into engagement with the backing strip 1 as it enters the first turn of the backing around the capstan wheel.
• the knurling tool 3 has a knurling wheel mounted on a rod movable in the support block 6 in the position offset laterally from the cutting tool 2 so that it engages the backing strip in the second turn thereof around the capstan wheel 9. This spaces the cutting and knurling tools and isolates them so that the backing strip is not placed under strain, as would be the case if the knurling and cutting tool were in close proximity to each other.
• Ultrasonic welding is enhanced by virtue of the lack of strain in the base of the channel 16 of the backing strip, where the weld section is formed.
• a channel is formed in the backing by means of a plow which is disposed centrally of the width of the backing strip.
• the flanges are the furrow which is made by the plow.
• the inside wall of the flanges and the base of the channel are stressed by the plowing process and may contain stress fractures.
• the formed backing strip is guided to the machine which fabricates the yam loops and feeds the backing strip so that the loops of yam enter the channel 16 and are then ultrasonically welded, such as shown in the above referenced Horton and Johnson patents.
• the cutting tool 2 and knurling tool 3 are movable into the side of the backing strip 1 which is exposed on the capstan wheel 9 by means of screw micrometer adjustment mechanisms 4. When advanced to the desired penetration depth by the micrometer mechanisms 4, the tools 2 and 3 are locked in place by tool position lock screws 5.
• the cutting tool 2 has spaced chisel cutting edges 2a and 2b. These edges upset and cold form the flanges 15. They leave the base pristine and strain free while removing material between the flanges and the edges of the backing strip which creates indentation or notches.
• the channel 16 is precisely defined with a strain free base.
• the notches 17 have the additional advantage of reducing the thickness of the backing strip 1 and enabling it to be flexible and bending about the width of the backing strip. This bending or hinging action makes the insertion of the backing strip in a T-slot of a window or frame, such as shown at 22 in FIGS. 9, 10, and 11A, easier to be accomplished especially by mechanisms for rolling the weatherstrip into the T-slot.
• the spacing of the chisel cutting edges 2a and 2b may be adjustable by inserting spacer blocks 25 of different width.
• the alignment of the chisel parts 2a and 2b is maintained by alignment pins 23 and the parts are held in place by a support screw 29 (see FIG. 8).
• the welding of the yarn loops in the channel 16 may be facilitated by texturing the base. Such texturing is accomplished by means of the knurling tool 3.
• the knurled surface 18 (see FIG. 5) may present a greater area than the pristine surface as shown in FIG. 4, and may be easier to melt with less ultrasonic energy. Accordingly, although the use of a knurled channel base is optional, it is presently preferred.
• the thickness reduction in the notches 17 enables the backing strip 1 to be bent and deflected so as to be permanently set and form the arcuate (concave or convex) shapes as shown in FIGS. 9 and 10. These shapes result in points of contact as indicated at 14 in FIGS. 9 and 10 with the interior walls of the T-slot.
• the longitudinal movement of the weatherstrip in the T-slot is thereby reduced in the manner similar to the nubbins shown in Johnson, U.S. Patent 5,438,802, referenced above. Cold forming to provide the convex or concave shapes may be accomplished with rolling tools having the desired shape.
• Such cold fonning is preferably performed after the weatherstrip is fabricated in the machine such as shown in above-referenced Horton and Johnson patents but before installation in the T-slot.
• the backing strip 1 may also be cold formed into shapes shown in FIGS. 11A and 1 IB having longitudinal waves with indentations and ridges. The ridges on successive undulations or waves are on opposite sides of the backing. This enhances the seal in the T-slot as well as the frictional, interference fit of the weatherstrip in the T-slot.
• Weatherstrips having shaped backing strips as shown in FIGS. 9, 10 and 11 are preferably inserted into the T-slot from one end thereof, rather than rolled through the throat of the slot.
• the cutting tool 2 and the knurling tool 3 are backed away from the capstan wheel 9 to enable the backing strip 1 to be threaded into the apparatus around the guide wheels 10 and 12 and to wrap the pair of turns on the periphery of the capstan wheel 9.
• the cutting tool 2 and the knurling tool 3 are advanced by the micrometer adjustment mechanisms 4 until contact with the backing strip is made so as to calibrate the micrometer mechanisms 4 at the position where the tools 2 and 3 just touch the surface of the exposed side of the backing strip 1 on the capstan wheel 9. Then the micrometer mechanisms are advanced so that the tools 2 and 3 are inserted to the requisite penetration depth into the backing strip 1. The lock screws 5 are then tightened and the support guides 7 is adjusted to prevent the backing strip from wandering laterally on the capstan wheel 9.
• the one-way clutch 28 enables the capstan wheel 9 to be manually rotated clockwise. This pulls the backing strip 1 through the tools 2 and 3 so as to form the backing strip into the desired profile with the flanges and notches.
• the backing strip 1 is then measured to ensure that the profile is correct.
• the motor that rotates the shaft 8 and the capstan wheel 9 is then engaged to continuously form the backing strip.
• the backing strip is then fed to the weatherstrip fabricating machine, which may be a machine of the type described in the above-referenced Horton and Johnson patents, which are incorporated herein by reference.
• the yarn pile once ultrasonically welded to the backing strip 1 may provide a unitary brush or a member for a brush.
• the yam providing the brush bristles may be made of substantially stiff material, the degree and composition of such depending on the brush application.

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• Engineering & Computer Science (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Lining Or Joining Of Plastics Or The Like (AREA)
• Seal Device For Vehicle (AREA)
• Vehicle Waterproofing, Decoration, And Sanitation Devices (AREA)
• Specific Sealing Or Ventilating Devices For Doors And Windows (AREA)
• Sealing Devices (AREA)

Priority Applications (9)

Applications Claiming Priority (1)

Publications (1)

Family

ID=29581746

Family Applications (1)

Country Status (8)

Cited By (4)

Families Citing this family (1)

Citations (1)

• 2002
  • 2002-05-24 EP EP02734546A patent/EP1507909A1/en not_active Withdrawn
  • 2002-05-24 CA CA002444190A patent/CA2444190A1/en not_active Abandoned
  • 2002-05-24 KR KR10-2003-7012087A patent/KR20050005732A/ko not_active Application Discontinuation
  • 2002-05-24 AU AU2002305709A patent/AU2002305709A1/en not_active Abandoned
  • 2002-05-24 MX MXPA04000762A patent/MXPA04000762A/es unknown
  • 2002-05-24 JP JP2004507587A patent/JP2005526937A/ja not_active Ceased
  • 2002-05-24 WO PCT/US2002/016612 patent/WO2003100151A1/en not_active Application Discontinuation
  • 2002-05-27 TW TW091111193A patent/TW564282B/zh not_active IP Right Cessation

Patent Citations (2)

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