Static structures (e.g. – buildings) – In situ attached-type channel or trim strip – Water-guard
Reexamination Certificate
1999-07-06
2001-11-06
Redman, Jerry (Department: 3634)
Static structures (e.g., buildings)
In situ attached-type channel or trim strip
Water-guard
C052S097000, C296S213000
Reexamination Certificate
active
06311450
ABSTRACT:
FIELD OF THE INVENTION
The present invention generally relates to an apparatus and method for forming an extrusion member. More particularly, the present invention pertains to an apparatus and method for forming an extrusion member in which a resin layer of gradually changing cross-section or width is formed on a metal member also having a gradually changing cross-section or width.
BACKGROUND OF THE INVENTION
As shown in
FIG. 10
, vehicles typically include a roof drip molding disposed between the vehicle body and the door frame. In the past, this roof drip molding has been manufactured so as to possess a constant cross-section. Recently, in order to improve its design and appearance, the roof drip molding has been manufactured to possess a gradually changing cross-section along a portion of its length. For example, Japanese Patent Publication No. 5-62088 discloses a molding having a gradually changing cross-section and made of a plurality of parts. As seen in FIG.
11
(
a
), the molding includes a main body
102
, a garnish or ornamental portion
104
, and a retainer
106
which is adapted to provide water sealing characteristics. The main body
102
, which possesses a constant cross-section along its length, is formed by rolling a piece of metal, extruding a plastic layer onto the metal piece and then subjecting the main body to a bending operation to bend the front portion
102
′ relative to the center portion
102
″ of the main body. A portion of the metal in the main body
102
is exposed to form a shiny part of the molding while the portion of the metal that is covered by the plastic layer forms a non-shiny part of the molding.
The garnish or ornamental portion
104
is formed by stamping a metal piece and then injection molding a plastic layer onto the metal piece. A portion of the metal of the ornamental portion
104
is exposed to form a shiny part that aligns with the shiny part on the main body
102
after assembly, and the remaining portion of the metal piece that is covered with the plastic forms a non-shiny part of the ornamental portion
104
. The non-shiny part of the garnish portion
104
possesses a gradually changing cross-section.
The retainer
106
is formed by rolling a piece of metal and then subjecting the metal piece to a bending operation. The garnish
104
and the retainer
106
are then assembled to one another by welding to form a rear portion of the main body. The resulting rear portion of the main body is then assembled with the main body
102
to form the molding. The molding thus possess a front portion and center portion of constant cross-section or width, and a rear portion (formed by the garnish and retainer) having a changing cross-section or width.
This construction of the molding and method of manufacturing the molding suffers from a variety of drawbacks and disadvantages. In one respect, several different parts must be formed to produce the ultimate molding. This method also requires a variety of different process steps, thus increasing the cost and time associated with manufacturing the molding. Further, when the rear portion of the main body is assembled with the remainder of the main body, a seam is formed between the two parts. This seam can have a negative influence on the appearance of the molding and can adversely affect the water sealing capabilities of the molding.
Another known construction of a roof drip molding is illustrated in FIG.
11
(
b
) and includes a main body
110
, a garnish or ornamentation portion
112
and a retainer
114
. The main body
110
includes a front portion
116
, a center portion
118
and a rear portion
120
. The main body
110
is formed by rolling a strip of metal and applying a plastic layer along the length of the metal strip through extrusion. The width of the plastic layer is constant throughout the length of the main body and a portion of the metal strip is exposed to provide a shiny part on the main body
110
. A portion of the plastic layer in the area of the rear portion of the main body is then removed through appropriate operations and the rear portion
120
of the main body
110
is then bent to produce the main body seen in FIG.
11
(
b
).
The garnish or ornamental portion
112
is formed by injection molding and possesses a changing cross-section or width. The retainer
114
is formed by rolling a piece of metal and subjecting it to a bending operation. The garnish
112
and the retainer
114
are then assembled together, with the resulting piece being welded to the main body
110
.
This construction of the molding suffers from drawbacks and disadvantages similar to those discussed above. The numerous parts and operations needed to manufacture the molding significantly increases the cost associated with the molding. Further, the seam that is created by the assembly of the parts can adversely affect the water sealing capabilities of the molding.
SUMMARY OF THE INVENTION
Accordingly, a need exists for an apparatus and method for forming an extrusion member having a gradually changing cross-section defined by a gradually changing shiny portion and a gradually changing non-shiny portion.
A need also exists for an apparatus and method which avoid the problems mentioned above concerning application of a uniform layer of resin.
In light of the foregoing, the present invention provides an apparatus for applying a resin layer of varying width to a surface portion of a supporting member having a varying width. The apparatus includes a stationary die in which is provided a cavity, a resin passage in the cavity, and an injector disposed at the outlet of the resin passage. An extruder is provided for extruding resin material into the cavity via the resin passage. A sliding shutter mechanism is disposed in the cavity for varying the width-wise extent over which the resin is applied to the surface portion of the supporting member to permit application of a resin layer of varying width to the surface portion of the supporting member. A control unit is connected to the extruder and the shutter mechanism for controlling extrusion of the resin and the position of the shutter within the cavity.
The present invention also includes a receiving die that is designed to support the rear side of the supporting member during extrusion of the resin material. In one form of the invention, the receiving die is an eccentric device having a portion of greater width for supporting the rear side of the supporting member during application of a resin layer of relatively greater width and a smaller width portion for supporting the rear side of the supporting member during application of a resin layer of relatively smaller width. In another form of the invention, the receiving die is in the form of a plurality of sliding plates.
According the another aspect of the invention, a method for applying a resin layer of varying width on the surface of a supporting member having a varying width involves advancing a supporting member in a feed direction into a stationary die, wherein the stationary die has a cavity, a resin passage in the cavity, and a movable shutter mechanism disposed in the cavity. Resin material is extruded into the cavity via the extrusion passage to apply a layer of resin material to the surface of the supporting member. During the extrusion of the resin material and the advancement of the supporting member through the stationary die, the shutter mechanism is moved to vary the width of the resin layer applied to the surface of the supporting member so that the supporting member exiting the stationary die has an applied resin layer of varying width.
Another aspect of the invention involves an apparatus for applying a resin layer of varying width to a surface portion of a supporting member having a varying width, wherein the apparatus includes a stationary die in which is provided a cavity, a resin passage, and an injector disposed at an outlet of the resin passage, with the stationary die being provided with an opening through which the supporting member is advanced. An extruder extrudes resin
Kimura Hirohisa
Koide Yoshito
Nagata Kanehiro
Tanigaki Tsuyoshi
Aisin Seiki Kabushiki Kaisha
Burns Doane , Swecker, Mathis LLP
Redman Jerry
LandOfFree
Molding having a resin layer of varying width applied to a... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Molding having a resin layer of varying width applied to a..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Molding having a resin layer of varying width applied to a... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2575283