Flexible molding application tool

An improved tool for, and a method of, crimping weatherstrips in an essentially continuous motion along the in-place weatherstrip, e.g. about a door flange or the like. the head is provided with a handle extending from the top therefrom at a convenient angle to allow an operator to assume a position alongside the door flange. The handle, or at least the grip thereof, is capable of swiveling about the longitudinal axis of the handle, to reduce stress on the hands, wrists, and arms of an operator by permitting guiding motion of the tool ahead around the door flange while minimizing the amount of turning of arms or hands, or re-positioning of the operator's body, as the tool is caused to progress entirely along the length of the weatherstrip. This length is often the entire perimeter of the door opening. In using this improved tool to perform the crimping operation, the operator can move his/her arm in a generally circular motion, causing the tool head to follow the door opening flange, while the swivel handle accommodates the changes in angle as this motion proceeds. Another feature of the invention is the provision of a spring-loaded crimping roller pivotally mounted on the tool head, in opposition to a fixed crimping roller. Preferably, both crimping rollers are power driven. This allows the axes of the crimping rollers, and the spacing between them, to vary as the tool progresses in its action, so as to accommodate changes in thickness of the door opening flange.

FIELD OF THE INVENTION 
This invention relates to an improved tool for applying flexible molding, 
such as weatherstrip, to the perimeter of an opening, particularly a door 
opening in a vehicle body, wherein in the tool is easily manipulated to 
follow irregular and hard to access borders of such openings. 
BACKGROUND OF THE INVENTION 
There have been problems with the fitting of flange mounted automotive 
weatherstrips because of the manufacturing tolerances for both the 
weatherstrip and the vehicle. The flange to which the weatherstrip is 
fitted can have multiple thicknesses of sheet metal, and if the 
weatherstrip is pre-formed to accommodate these different thicknesses, it 
may be too wide for the single layer thicknesses and too narrow for the 
multiple layer thicknesses. As a result, the weatherstrip may not grip 
satisfactorily where the flange is of one layer, and if the flange 
consists of two or more layers, the weatherstrip may be extremely 
difficult to install in some places, and loose in others. 
The weatherstrips have in recent years developed into complex 
cross-sections. They include the basic U-shaped central section, and 
optional internal ribs, and an embedded metal carrier which will maintain 
the shape of the central section. The weatherstrips are supplied to the 
assembly plant with the central section (and carrier) partially closed. 
This provides a cross-section with a low insertion effort for easy 
installation. This central section is applied to the vehicle opening 
flange by hand, beginning at some convenient index point. Various forms of 
lips and/or bulb sections may be provided on the exterior walls of the 
central section. A tool is then used to crimp the central section directly 
onto the flange. 
The weatherstrips are fitted by an assembler in a loosely closed condition 
onto the opening (door) flanges on an assembly line, then formed by the 
tool to close the central section against the flanges, thus producing the 
desired final profile where the weatherstrip is tightly crimped in its 
functional position. This final forming operation is performed on line in 
the vehicle assembly plant utilizing a tool of the type disclosed herein. 
Thus, instead of a final stage of forming (as by rolls) at the end of the 
strip manufacturer's extrusion, as has been done in the past, and 
encountering the potential of distortion during packing and shipping, a 
hand-held roll-forming tool is used to post-form the weatherstrip directly 
onto the door flange, ensuring perfect sealing characteristics. 
Present tools consist of a standard in-line pneumatic motor tool which 
drives two cylindrical counter-rotating rollers at its forward end. The 
necessary gears and bearings are housed in a case that is attached to the 
motor output shaft. The air motor is equipped with an activation lever 
which controls a valve in the air supply to the motor, to control rotation 
of the rollers. 
The rollers are a predetermined fixed distance apart and revolve in 
opposite directions (e.g. an inward nip) thus applying pressure on the 
profile of the central section as these rollers are advanced along the 
weatherstrip already placed on the door flange. To use these tools 
correctly, the rollers must be kept in the correct relationship to the 
weatherstrip and flange during excursion of the tool around the opening. 
Specifically, the axes of the rollers must be maintained parallel to the 
flange surface. Also, the angle of the tool head should be kept at a 
certain inclination (e.g. inclined 5 degrees to 10 degrees towards the 
direction of travel) to start and maintain proper engagement of the 
rollers against the weatherstrip. If that inclination is too small or away 
from the direction of travel, then the tool will tend to move off the 
weatherstrip. The relatively heavy and off balance tool makes this action 
difficult and stressful. 
SUMMARY OF THE INVENTION 
The present invention provides an improved tool for the operation of 
crimping such weatherstrips and the like in an essentially continuous 
motion along the in-place weatherstrip, e.g. about a door flange or the 
like. This tool incorporates an air motor in the tool head, and the head 
is provided with a handle extending from the top therefrom at a convenient 
angle to allow an operator to assume a position alongside the door flange. 
The handle, or at least the grip thereof, is capable of swiveling about 
the longitudinal axis of the handle, to reduce stress on the hands, 
wrists, and arms of an operator by permitting guiding motion of the tool 
head around the door flange while minimizing the amount of turning of arms 
or hands, or re-positioning of the operator's body, as the tool is caused 
to progress entirely along the length of the weatherstrip. This length is 
often the entire perimeter of the door opening. In using this improved 
tool to perform the crimping operation, the operator can move his/her arm 
in a generally circular motion, causing the tool head to follow the door 
opening flange, while the swivel handle accommodates the changes in angle 
as this motion proceeds. 
Another feature of the invention is the provision of a spring-loaded 
crimping roller pivotally mounted on the tool head, in opposition to a 
fixed crimping roller. Preferably, both crimping rollers are power driven. 
This allows the axes of the crimping rollers, and the spacing between 
them, to vary as the tool progresses in its action, so as to accommodate 
changes in thickness of the door opening flange.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to the drawings, particularly to FIGS. 10 and 11, a typical 
modern weatherstrip 20 is shown in cross-section, including an internally 
ribbed main or central section 22 which incorporates a conventional metal 
skeleton 23, and also has attached to it a lip portion 24, and a hollow 
collapsible bulb portion 25; the lip portion and bulb are typical of newer 
forms, but are not necessary parts in various other configurations of 
weatherstrip. FIG. 10 shows such a strip placed on a door flange 28, the 
central section having already been fitted about flange 28 in the act of 
placing the weatherstrip manually. This action bends the carrier sides 
initially inward. FIG. 11 illustrates the action of the crimping rollers 
of the tool, which is described below. 
FIG. 1 is a view from the top of the tool, illustrating the overall 
configuration of main housing 30 and swiveling handle 35. Housing 30 has a 
top, a front end and rear end, and a first side, and second side. The 
angular relationship of handle 35 to housing 30 can be seen by comparison 
of FIGS. 1 and 4. The handle extends upward, outward, and rearward of 
housing 30, being fastened at an angle to top, near to front end. An air 
motor 40, preferably of the vane type, is incorporated within housing 30, 
and has an output shaft 42 to which is fastened the main drive gear 44 
(FIG. 3). 
A first output drive shaft 45 is supported along a fixed axis by bushings 
in housing 30, the forward bushing shown at 47, and a first driven gear 48 
is fixed to shaft 45, meshing with main drive gear 44 (FIGS. 1 and 3). An 
idler gear 50, rotatable on the end of a pivot pin 54 in the forward end 
of housing 30, also meshes with drive gear 44. On the side of housing 30 
opposite shaft 42, there is an elongated separate small support block, 52 
having supporting ears 53 which are engaged around the pivot pin 54 fitted 
into housing 30. A second output drive shaft 55 is rotatably supported by 
bushing 56 in the small housing 52, and a second driven gear 58 is fixed 
to shaft 55, meshing with idler gear 50. Thus, shafts 45 and 55 are 
supported in main housing 30, and extend from the front end 32. 
A leaf spring 60 is anchored in housing 30 (as by screws, not shown, in its 
lower edge) proximate to pivot pin 54, and extends upward and outward, as 
shown in FIG. 3, resting against the separate second housing 52 and urging 
it into contact with the adjacent side of housing 30. Thus, driven gear 58 
can move in an arc about pivot pin 54 while maintaining mesh with idler 
gear 50. This action allows the parallel centerlines of drive shafts 45 
and 55 to be separated while the gears all remain in mesh. 
Referring particularly to FIG. 4, handle 35 includes an angular handle 
adaptor 65 having an appropriately angled face which is bolted to housing 
top 31 near to the front-end 32. Adaptor 65 is located on a longitudinal 
handle axis which is inclined upward and outward toward housing rear end 
33, and also outward of the first housing side 34A. The handle adaptor 65 
includes a rearwardly extending cylindrical part 66 having a pair of 
spaced apart circumferential grooves 67 receiving O-ring seals 68, and a 
snap ring retainer groove 70 into which a retaining snap ring 72 can be 
fitted. A cylindrical throttle adapter 75 fits over the part 66, is held 
thereon by snap ring 72, and presents a threaded end 76 to internal 
threads of the throttle handle assembly 78. The throttle handle assembly 
is a conventional part, used in various forms in a number of compressed 
air driven tools. 
A control lever 80 is pivotally supported on the outward end of the 
throttle handle assembly 78, and controls the opening of an air valve 82 
of conventional construction, normally spring biased closed, in the 
throttle handle assembly. Lever 80 is arranged to open valve 82 when the 
lever is squeezed against the throttle handle assembly. Outward of valve 
82 is the fitting for the air supply hose. This fitting contains a 
metering unit 84 and a standard swiveling air coupling 85. In operation, 
the fingers of the hand of the operator holding the throttle handle 
assembly grip over lever 80 so the operator squeezes the lever to start 
the internal air motor. 
FIGS. 5 and 6 show the end cap 90 which is attached to the front end 32 of 
housing 30, covering the gears. The crimping rollers 92 (fixed axis) and 
94 (movable axis) are shown fitted to the ends of drive shafts 45 and 55. 
They are secured on shafts 45, 55 by suitable screws 95S, 96S. A set of 
guide rollers 95, 96 are supported by brackets 98 above and below the 
crimping rollers, extending at right angles to drive shafts 45, 55. These 
guide rollers are freely rotatable and provide a form of depth stop for 
the insertion of the crimping rollers around a weatherstrip and a low 
friction guide which helps to maintain the tool in proper position as it 
travels along a weatherstrip, performing the crimping function. 
The tool is engaged about an in-place weatherstrip by powering the crimping 
rollers 92, 94 as they enter onto opposite sides of the strip, and the 
tool is then maneuvered to place the guide rollers 95, 96 against the face 
of the strip and hold them in that position as the powered rollers carry 
the tool along the strip while performing the crimping function. When a 
curve is encountered, the operator can merely exert pressure through the 
handle and housing to keep the tool tracking properly along the strip. The 
handle will swivel as this motion continues, so the operator does not need 
to twist his hands, wrists or arms to any extent to follow this motion 
entirely around an opening, or on any irregular path. 
While the method herein described, and the form of apparatus for carrying 
this method into effect, constitute preferred embodiments of this 
invention, it is to be understood that the invention is not limited to 
this precise method and form of apparatus, and that changes may be made in 
either without departing from the scope of the invention, which is defined 
in the appended claims.