Panel units having in situ formed moldings

Abstract

Methods for manufacturing panel units may include applying a cover tape to a surface of a panel in such a way as to substantially extend along a periphery of the panel. An extrusion molding die may be moved relative to the panel in such a way that the extrusion molding die moves along the periphery of the panel while at least partially contacting the cover tape applied to the panel. At the same time, a molten molding material may be extruded from the extrusion molding die, thereby integrally forming a molded article on the periphery of the panel. The cover tape may be then removed from the surface of the panel in order to produce a panel unit having the molded article disposed along the periphery of the panel.

What is claimed is:  
     
         1 . A method for manufacturing a panel unit comprising: 
 applying a cover tape to a surface of a panel so as to substantially extend along a periphery of the panel,    moving an extrusion molding die relative to the panel so that the extrusion molding die moves along the periphery of the panel while at least partially contacting the cover tape applied to the panel and    simultaneously extruding a molten molding material from the extrusion molding die, thereby integrally forming a molded article along the periphery of the panel.    
     
     
         2 . A method as defined in  claim 1 , further comprising removing the cover tape from the surface of the panel after the molded article has been formed.  
     
     
         3 . A method as defined in  claim 1 , further comprising applying an adhesive layer to the periphery of the panel before extruding the molten molding material.  
     
     
         4 . A method as defined in  claim 3 , wherein the adhesive layer overlaps at least a portion of the cover tape.  
     
     
         5 . A method as defined in  claim 1 , further comprising trimming the cover tape along a peripheral edge of the surface of the panel after it has been applied to the panel surface and before extruding the molten molding material.  
     
     
         6 . A method as defined in  claim 1 , wherein the molded article has a peripheral edge that conforms to a peripheral edge of the surface of the panel.  
     
     
         7 . A method as defined in  claim 1 , further comprising partially cutting away the cover tape along the periphery of the panel before extruding the molten molding material, thereby forming an uncovered panel surface portion extending along the periphery of the panel, and further comprising forming the molded article with an extension that partially covers the surface of the panel.  
     
     
         8 . A method as defined in  claim 7 , further comprising cutting away the cover tape to provide a cutting surface that is inclined at an acute angle relative to the panel surface, wherein an end surface of the extension is inclined at an obtuse angle relative to the panel surface.  
     
     
         9 . A method as defined in  claim 1 , further comprising forming the molded article with a covering portion that covers at least a portion of the cover tape and cutting the covering portion and the cover tape along the periphery of the panel.  
     
     
         10 . A method as defined in  claim 9 , further comprising removing the cover tape from the panel surface, thereby forming the molded article with an extension that partially covers the panel surface.  
     
     
         11 . A method as defined in  claim 10 , further comprising cutting the covering portion and the cover tape so that the extension has a cutting surface that is inclined at an obtuse angle relative to the panel surface.  
     
     
         12 . A method as defined in  claim 10 , further comprising interleaving a portion of the cover tape between the extension and the panel surface.  
     
     
         13 . A method as defined in  claim 1 , further comprising extruding the molded article so as to cover an opposite surface and an end surface of the panel.  
     
     
         14 . A method as defined in  claim 1 , further comprising extruding the molded article so as to cover the surface, an opposite surface and an end surface of the panel.  
     
     
         15 . A method as defined in  claim 1 , wherein the panel is a window pane that comprises glass or resin and the method further comprises trimming the cover tape along a peripheral edge of the window pane surface and disposing an adhesive layer along the periphery of the window pane before extruding the molten material.  
     
     
         16 . A method as defined in  claim 1 , wherein the panel is a window pane that comprises glass or resin and the method further comprises partially cutting away the cover tape along the periphery of the window pane, thereby forming an uncovered panel surface portion extending along the periphery of the window pane and disposing an adhesive layer on the periphery of the window pane before extruding the molten molding material.  
     
     
         17 . A method as defined in  claim 1 , wherein the panel is a window pane that comprises glass or resin and the method further comprises trimming the cover tape along a peripheral edge of the window pane, disposing an adhesive layer on the periphery of the window pane before extruding the molten material, cutting a portion of the molding article and the cover tape along the periphery of the window pane after the molten material has been extruded and removing the cover tape from the window pane surface, thereby producing a window pane unit that includes the molded article covering the surface, an opposite surface and an end surface of the window pane.  
     
     
         18 . A method as defined in  claim 1 , wherein the panel comprises glass or resin and the method further comprises: 
 applying an adhesive layer to the periphery of the panel before extruding the molten molding material, wherein the adhesive layer overlaps at least a portion of the cover tape, forming the molded article with a covering portion that at least partially covers the adhesive layer and the cover tape, and    cutting the covering portion, adhesive layer and cover tape at an oblique angle with respect to the panel surface and removing the distal portion of the covering portion, adhesive layer and cover tape, thereby forming the molded article with an extension, wherein the cover tape and the adhesive layer are interleaved between the covering portion and the panel surface.    
     
     
         19 . A method as in  claim 18 , wherein the cover tape has a thickness of about 0.03 to 1.0 mm and comprises a first layer comprising a synthetic resin and a second layer comprising a removable self-adhesive material.  
     
     
         20 . A panel unit formed by the method of  claim 18 , comprising: 
 the panel comprising glass or resin,    the in situ formed molding formed along a peripheral edge of the panel by extruding a molten or substantially liquid molding material according to  claim 18 , the in situ formed molding having the extension that partially covers the surface of the panel and the end surface of the extension is inclined at an obtuse angle relative to the panel surface, and    the cover tape and adhesive layer interleaved between the extension of the in situ formed molding and the panel surface.    
     
     
         21 . A panel unit as in  claim 20 , wherein the cover tape has a thickness of about 0.03 to 1.0 mm and comprises a first layer comprising a synthetic resin and a second layer comprising a removable self-adhesive material.  
     
     
         22 . A panel unit formed by the method of  claim 1 , comprising: 
 the panel,    the in situ formed molding formed along a peripheral edge of the panel by extruding a molten or substantially liquid molding material according to  claim 1 , and    the cover tape applied according to  claim 1  and disposed on the panel surface substantially adjacent to the in situ formed molding.    
     
     
         23 . A panel unit as in  claim 22 , wherein the cover tape has a width between about 1 to 5 centimeters and a thickness of about 0.03 to 1.0 mm and comprises a first layer comprising a synthetic resin and a second layer comprising a removable self-adhesive material.  
     
     
         24 . A panel unit, comprising: 
 a panel comprising glass or resin,    an in situ formed molding formed along a peripheral edge of the panel by extruding a molten or substantially liquid molding material, the in situ formed molding having an extension that partially covers a surface of the panel and an end surface of the extension is inclined at an obtuse angle relative to the panel surface, and    a cover tape disposed between the extension of the in situ formed molding and the panel surface.    
     
     
         25 . A panel unit as in  claim 24 , wherein the cover tape has a thickness of about 0.03 to 1.0 mm and comprises a first layer comprising a synthetic resin and a second layer comprising a removable self-adhesive material.  
     
     
         26 . A panel unit, comprising: 
 a panel,    an in situ formed molding formed along a peripheral edge of the panel by extruding a molten or substantially liquid molding material, and    a cover tape disposed on the panel surface substantially adjacent to the in situ formed molding.    
     
     
         27 . A panel unit as in  claim 26 , wherein the cover tape has a width between about 1 to 5 centimeters and a thickness of about 0.03 to 1.0 mm and comprises a first layer comprising a synthetic resin and a second layer comprising a removable self-adhesive material.