Laminate flexible strip and method for making same

Abstract: A laminate flexible strip (10) includes a core member (12) having a cover layer (14) disposed about the core member. The core member comprises a plurality of longitudinally spaced clamping clips (16) and a plurality of laterally spaced fibres (18) attached to the clips to allow the core to flex longitudinally and laterally.

Description: The present invention relates to a laminate flexible strip. More particularly, the present invention relates to trim strips adapted to automotive vehicles. Laminated trim strips have been used in the past to act as a sealing strip around a door in a vehicle. Typically, the trim strip comprises a core member having a cover layer disposed about the core member. Examples of such trim strips are disclosed in US-A-3 197 821 US-A-3 310 928 and US-A-4 413 033. The problem with such trim strips is that the core member may be flexible in only one direction, such as longitudinally, Also, woven wire cores must use non-functional wire connecting loops. Similarly, stamped cores may waste up to 50% of the material in slug loss and non-functional connecting strips. This results in less than 100% material utilization. Further, the core members are complex and costly manufacture. Patent Abstracts of Japan Vol. 7, No. 47 (M-196) (1192) relating to JP-A-57195967 discloses a core member according to the preamble of claim 1, having longitudinally spaced and laterally extending metal supporting pieces and a pair of laterally spaced and longitudinally extending coupling bodies which are attached to the supporting pieces by an adhesive which is temperature sensitive and broken down upon heating. Patent Abstracts of Japan Vo. 7, No. 98 (M-210 (1243) relating to JP-A-5820541 discloses a rubber trim for automobiles having a cloth-like core member formed from longitudinally spaced and laterally extending reinforcing materials (e.g. glass fibre or carbon fibre) and laterally spaced and longitudinally extending connecting members (e.g. of glass single yarn, or cotton yarn). The components of the core member are strengthened by being impregnated with a thermosetting resin. The core member is then coated with a rubber cover layer and bent into shape. US-A-4 710 416 discloses a trim having a core member formed from a plurality of longitudinally spaced and laterally extending metal core segments connected by laterally spaced and longitudinally extending strips of adhesive tape, which may be positioned on one or both sides of the core segments. The core member is then covered by a rubber or synthetic resin outer casing and bent into shape. DE-A-2 030 801 discloses a trim strip having a wire structure for a core member which is formed by longitudinally spaced and laterally extending weft wires and longitudinally extending warp wires which weave in and out along the centre of the weft wires leaving their edges free (to thereby give greater flexibility to the structure). The weft wires are provided with a plastics coating into which the warp wires are fixed. The wire structure is then provided with a cover layer and bent into shape. According to the present invention there is provided a flexible strip for attachment to a vehicle which comprises a core member bent to a predetermined configuration and a cover layer disposed about the core member, wherein the core member comprises a plurality of longitudinally spaced and laterally extending clamping clips and a plurality of laterally spaced and longitudinally extending linear fibres connected to the clips which allow the core member to flex longitudinally and laterally, the arrangement being such that a first plurality of apertures is formed between the clips and a second plurality of apertures is formed between the fibres, characterized in that the strip further includes a filler filling the first and second plurality of apertures so that the core member has a substantially smooth continuous outer surface. According to the present invention there is also provided a method of making a flexible strip according to the invention which method comprises the steps of forming a plurality of laterally spaced fibres; forming a plurality of longitudinally spaced clamping clips; assembling the fibres and clips to form a core member capable of flexing longitudinally and laterally, in which the clips are longitudinally spaced and laterally extending and the fibres are laterally spaced and longitudinally extending so that a first plurality of apertures is formed between the clips and a second plurality of apertures is formed between the fibres; filling the apertures between the clips and between the fibres so that the core member has a substantially smooth continuous outer surface; and extruding a cover layer about the core member. A laminate flexible strip includes a core member having a cover layer disposed about the core member. The core member comprises a plurality of longitudinally spaced clamping clips and a plurality of laterally spaced fibers attached to the clips to allow the core to flex longitudinally and laterally. Accordingly, the present invention allows the core member to flex longitudinally and laterally. Also, the core member has 100% material utilization. Further, the core member of the present invention is simpler and less expensive to manufacture than conventional cores. Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: Figure 1 is a partial fragmentary view of one embodiment of the present invention; and Figure 2 is a schematic drawing illustrating the method of making a strip according to the present invention; eg the embodiment of Figure 1. A laminate flexible strip for attachment to a vehicle (not shown) is generally shown at 10 in Figure 1. The strip 10 comprises a core member generally indicated at 12, and a cover layer 14 of elastomeric material disposed about the core member 12. The core member 12 comprises a plurality of discontinuous or non-connected longitudinally spaced and laterally extending metal clamping clips 16 and a plurality of continuous laterally spaced and longitudinally extending linear fibres 18 connected to the clips 16 to allow the core 12 to flex longitudinally and laterally. The fibres 18 may be made of a material dissimilar from the clips 16. The core member 12 includes first apertures 20 between the clips 16 and second apertures 22 formed between the fibres 18. The clips 16 are secured to the fibres 18 by an adhesive potting laminate. A filler material 24 is filled in the first 20 and second 22 apertures to present a smooth, continuous outer surface on the cover layer 14. In other words, the filler material 24 is disposed in the first 20 and second 22 apertures to eliminate a "hungry horse" effect on the outer surface of the cover layer 14 by the cover layers 14 sinking into the apertures 20, 22 when the core member 12 is formed or bent to a predetermined configuration such as a "U" shape. As mentioned above, a method of making a laminate flexible strip 10 for attachment to a vehicle is provided. An apparatus for performing the method is generally shown at 30 in Figure 2. The method comprises the steps of forming a core member 12 comprising a plurality of laterally spaced fibres 18 and a plurality of longitudinally spaced clamping clips 16. The steps include forming a cover layer 14 about the clips 16 and fibres 18 to form a strip 10 which is flexible longitudinally and laterally. More specifically, the steps include tensioning the fibres 18 in die 32 and extruding the fibres 18 by a fibre-coating cross-head extrusion 34. The steps further include feeding a metal stock 36 such as a strip to a cutting device 38 and cutting the stock 36 to a predetermined length with the cutting device 38 to form the clips 16. The steps include feeding the clips 16 to a magnetic roller 40. The clips 16 are held to the roller 40 by magnetic attraction. The roller 40 rotates as the fibres 18 are extruded and placed on the clips 16. The steps further include filling apertures 20, 22 between the clips 16 and fibres 18 by extruding a filler material 24 from die 42. The filler material 24 is formed to the proper thickness between the roller 40 and a rotating gauge roller 44. The core 12 is temperature conditioned at 46. Finally, the steps include extruding an elastomeric cover layer 14 about the clips 16 and fibres 18.

Claims: A flexible strip (1) for attachment to a vehicle which comprises a core member (12) bent to a predetermined configuration and a cover layer (14) disposed about the core member, wherein the core member comprises a plurality of longitudinally spaced and laterally extending clamping clips (16) and a plurality of laterally spaced and longitudinally extending linear fibres (18) connected to the clips which allow the core member to flex longitudinally and laterally, the arrangement being such that a first plurality of apertures (20) is formed between the clips and a second plurality of apertures (22) is formed between the fibres, characterized in that the strip further includes a filler material (24) filling the first and second plurality of apertures so that the core member has a substantially smooth continuous outer surface. A strip according to claim 1, which further includes securing means for securing the clamping clips to the fibres. A strip according to claim 1 or 2, wherein the clips are made of a material dissimilar from that of the fibres. A strip according to any preceding claim, wherein the cover layer is made of an elastomeric material. A method of making a flexible strip for attachment to a vehicle according to any one of claims 1 to 4, which method comprises the steps of: forming a plurality of laterally spaced fibres; forming a plurality of longitudinally spaced clamping clips; assembling the fibres and clips to form a core member capable of flexing longitudinally and laterally, in which the clips are longitudinally spaced and laterally extending and the fibres are laterally spaced and longitudinally extending so that a first plurality of apertures is formed between the clips and a second plurality of apertures is formed between the fibres; filling the apertures between the clips and between the fibres so that the core member has a substantially smooth continuous outer surface; and extruding a cover layer about the core member. A method according to claim 5, wherein the fibres are formed by tensioning followed by extrusion. A method according to claim 5 or 6, wherein the clips are formed by cutting a metal stock into predetermined lengths and wherein the process includes the step of feeding the clips to a magnetic roller by which they are held during manufacture of the core member. A method according to claim 5, 6 or 7, which includes the further step of bending the core member to a predetermined shape.

Inventors: KEYS JAMES FREDERICK, KEYS, JAMES FREDERICK
Applicants: STANDARD PRODUCTS CO, THE STANDARD PRODUCTS COMPANY
Application year: 1989
Main classification: B60R13
IPC codes: B60J10, D06N7, B29C69, B29C47