Systems and methods for manufacturing reinforced weatherstrip

Abstract

Methods for manufacturing fabric-reinforced weatherstrip include incorporating a fabric application step into a process for making coated substrates. In one embodiment, a strip of the fabric from a roll of material may be applied directly onto a coating after it has been applied in a coat die to a foam profile, while the coating is still in the molten state. Alternatively, a fabric application plate may be attached to an upstream side of coating die with a fabric feed channel cut into the plate. The fabric follows the channel to contact and mate with the foam profile. The fabric applicator plate may be configured so as to exert pressure on only the part of the product where the fabric is being applied. Ultrasonic welding techniques may also be employed.

What is claimed is: 
     
         1 - 25 . (canceled) 
     
     
         26 . A weatherstrip comprising:
 a foam profile;   a stiffener in mating contact with the foam profile; and   a coating layer substantially coating the foam profile, wherein at least a portion of the foam profile not in mating contact with the stiffener is not coated by the coating layer.   
     
     
         27 . The weatherstrip of  claim 26 , wherein the coating layer at least partially coats the stiffener. 
     
     
         28 . The weatherstrip of  claim 26 , wherein the portion of the foam profile not coated by the coating layer is covered by a fabric layer. 
     
     
         29 . The weatherstrip of  claim 26 , wherein the foam profile comprises an irregular elongate shape. 
     
     
         30 . The weatherstrip of  claim 29 , wherein the portion of the foam profile not coated by the coating layer is disposed proximate the stiffener. 
     
     
         31 . The weatherstrip of  claim 26 , wherein the foam profile comprises a hinge shape. 
     
     
         32 . The weatherstrip of  claim 31 , wherein the hinge is covered by a fabric layer. 
     
     
         33 . The weatherstrip of  claim 32 , wherein the fabric layer is at least partially covered by the coating layer. 
     
     
         34 . A weatherstrip comprising a contiguous exterior surface defined by a stiffener material, a coating material, and a foam material. 
     
     
         35 . The weatherstrip of  claim 34 , wherein the stiffener material comprises a polypropylene. 
     
     
         36 . The weatherstrip of  claim 35 , wherein the stiffener material comprises at least one barb. 
     
     
         37 . The weatherstrip of  claim 36 , wherein the stiffener material comprises a substantially L-shaped profile. 
     
     
         38 . The weatherstrip of  claim 37 , wherein the coating material comprises a resin. 
     
     
         39 . The weatherstrip of  claim 38 , wherein the coating material comprises a thermoplastic polymer. 
     
     
         40 . The weatherstrip of  claim 39 , wherein the coating material is non-contiguous about the foam profile. 
     
     
         41 . The weatherstrip of  claim 39 , wherein the thermoplastic polymer comprises at least one of such as an olefinic plastic/olefinic rubber blends, a partially or fully cross-linked rubber, a polyethylene, am ethylene/methacrylic acid copolymer, an ethylene/ethyl acrylate polymer, a linear low density polyethylene polymers, a linear low density polyethylene copolymer, an ethylene interpolymer/chlorinated polyolefin blend, an ionomers, a polypropylene copolymer, a polypropylene copolymer, a nylon, a polyester, and a thermoplastic polyurethane. 
     
     
         42 . The weatherstrip of  claim 40 , wherein the foam material comprises a low-density foamed thermoplastic elastomer. 
     
     
         43 . The weatherstrip of  claim 42 , wherein the foam material comprises a substantially hinge-shaped profile. 
     
     
         44 . A weatherstrip made according to a method comprising:
 providing a foam profile;   providing a stiffener;   attaching the stiffener to the foam profile; and   passing the foam profile and the stiffener through a resin coating die, wherein the resin coating die comprises a metering gap between the resin coating die and selected portions of the foam profile, wherein at least a portion of the foam profile is uncoated by resin upon exit from the coating die.   
     
     
         45 . The weatherstrip of  claim 44 , wherein the method further comprises applying a fabric layer to at least one of the foam profile and the resin coating.