Reinforcing cores or carriers for flexible products

Abstract: A reinforcing carrier for a flexible sealing, trimming, finishing or glass-guiding strip, for example, comprises two slotted blanks, such as made of metal, which are superimposed on each other, with one or more flexible longitudinal substantially inextensible members (28A,28B), such as made of wire, placed between them. The slotted blanks are then secured together to hold the longitudinal members (28A,28B) in predetermined positions, and the edge regions (26A,26B) are then broken off. In this way, the longitudinal members or wires (28A,28B) can be fixed in the required positions to achieve a desired location for the neutral bending axis of the finished carrier. The carrier may be bent into channel-form before or after incorporation into the plastics or rubber or similar material of the finished strip.

Description: The invention relates to a longitudinally extending reinforcing carrier for a flexible longitudinally extending strip, according to the preamble of claim 1, comprising longitudinally extending carrier element means, and at least one flexible longitudinal substantially inextensible member secured to and extending along the carrier element means at a predetermined position relative to its longitudinal axis. The invention also relates to a method of manufacturing a reinforcing longitudinally extending carrier for a flexible longitudinally extending strip, according to the preamble of claim 21, comprising the steps of forming longitudinally extending carrier element means, and securing at least one flexible longitudinal substantially inextensible member to and extending it along the carrier element means at a predetermined position relative to its longitudinal axis. Such a carrier and method are known from FR-A-2390668. This document discloses a carrier that is folded around a metal thread and crimped thereto. The carrier comprises a plurality of transverse bars coupled together by at least one longitudinally extending bar. Similar carrier and method are known from GB-A-1 556 655. In this known carrier, the flexible longitudinal substantially inextensible member is a wire which is individually welded to each carrier element. This is a difficult and time-consuming process. The invention is defined in the independent claims. Reinforcing carriers embodying the invention, and for use in sealing, trimming, finishing and glass-guiding strips used in motor vehicle body construction, will now be described, by way of example only, with reference to the accompanying diagrammatic drawings in which: Figure 1 is a perspective view showing an early stage in the manufacture of one of the carriers; Figure 2 is a perspective view showing a later stage in the manufacture of the carrier of Figure 1; Figure 3 is a perspective view showing a further stage in the manufacture of the carrier of Figures 1 and 2; Figure 4 is a plan view showing an initial stage in the manufacture of a second one of the carriers; Figure 5 is a plan view showing the following stage in the manufacture of the carrier of Figure 4; Figure 6 is a perspective view corresponding to Figure 5; Figure 7 is a perspective view showing a later stage in the manufacture of the carrier of Figures 4 to 6; Figure 8 is a perspective view showing a still further stage in the manufacture of the carrier of Figures 4 to 7; Figure 9 is a plan view of an early stage in the manufacture of a third one of the carriers; Figure 10 is a plan view showing the next stage in the manufacture of the carrier of Figure 9; Figure 11 is a perspective view corresponding to Figure 10; Figure 12 is a perspective view showing a further stage in the manufacture of the carrier of Figures 9 to 11; Figure 13 corresponds to Figure 12 but shows the following stage in the manufacture of the carrier of Figures 9 to 12; Figure 14 is an end view of a carrier according to the form shown in Figures 1 to 3, Figures 4 to 8 or Figures 9 to 13, bent into channel form and taken on the line XIV to XIV of Figure 15; Figure 15 corresponds to Figure 14 but shows a side view of the carrier curved to follow an "S" shape; Figure 16 corresponds to Figure 14 and is a section on the line XVI-XVI of Figure 17; Figure 17 is a side view of the carrier of Figure 16, curved to follow an "S" shape; Figure 18 corresponds to Figures 14 and 16 and is a section on the line XVIII-XVIII of Figure 19; Figure 19 is a side view of the carrier of Figure 18, curved to follow an "S" form; Figure 20 is a view corresponding to Figures 14,16 and 18 and is being a section on the line XX-XX of Figure XXI; Figure 21 is a side view of the carrier of Figure 20, curved to follow an "S" form; and Figure 22 is a cross-sectional view of a sealing strip embodying one of the carriers shown in the preceding Figures. The carriers to be described in more detail below may be used in channel-shaped form for reinforcing channel-shape sealing, trimming, finishing and glass-guiding strips used in motor vehicle body construction. Figure 22 shows, by way of example, a sealing strip 10 such as for fitting around the door frame in a motor vehicle body. The sealing strip 10 comprises a channel-shaped gripping portion 11 and a sealing portion 12. The gripping portion 11 comprises a channel-shaped carrier 13 incorporated into plastics or rubber or similar material 14. The material 14 may be produced by extrusion, with the carrier being incorporated into it during the extrusion process such as by using a cross-head extruder. The material 14 incorporates integral internal gripping lips 16. As shown in the Figure, the gripping portion 11 embracingly grips a mounting flange 18, which may be the flange running around the door opening of the motor vehicle, where the inner and outer body panels are welded together. The lips 16 help to ensure that the gripping portion 11 firmly grips the flange. The gripping portion 11 supports the sealing portion 12 which may be made of soft flexible material such as foamed plastics or rubber material. The sealing portion 12 may be integrally extruded with the material 14 or may be produced separately and secured thereto such as by adhesive. In this way, the gripping portion it supports the sealing portion 12 to run along the outside edge of the door opening so as to be partially compressed by the closing door (shown diagrammatically at 19), thus providing a weather seal. The carrier 13 is shown only generally in Figure 22. Various forms of the carrier will be described in detail below. The carrier is made of resilient material such as metal, and reinforces the material of the gripping portion 11 to ensure that it grips the flange 18 firmly. However, it should be understood that the carriers to be described in more detail below may be used in other forms of strip, such as window guide channels. In other applications of the carriers, they need not be in channel form and need not be for use in motor vehicle body construction. Strips incorporating the carriers may be required to be bent or curved in use. For example, the sealing strip shown in Figure 22 may need to be bent to follow curves at the corners of the door frame. It is important that the reinforcing carrier 13 not only permits such bending but ensures that the sealing strip follows the correct bending line and maintains a neat and pleasing appearance. In the manner to be explained, the carriers to be described in more detail below enable the position of the neutral bending axis of the strip to be adjusted and controlled; the neutral bending axis is the notional line along which neither compression nor tension occurs at a bend. In the form of the carriers to be described in more detail below, they comprise elements arranged tranverse or widthwise to the length of the carrier and side-by-side along the carrier, and interconnected in the form of a "ladder" by one or more flexible longitudinal elements in the form of wires, fibres or threads, which are positioned to control the neutral bending axis. The flexible longitudinal elements may be made of metallic wire, textile thread, glass fibre or other material which is flexible and preferably inextensible but enables longitudinal compression of the carrier. Figure 1 shows the first stage in the manufacture of one form of the carrier. A metal blank 22 is formed with slots 24 by a suitable cutting action. The blank 22 may be of predetermined length or it may be of generally indefinite length, being formed with the slots 24 as it is unwound from a drum or bobbin. Each slot 24 stops short of the edge portions 26A and 26B of the blank. Two slotted blanks, each of the form shown in Figure 1, are then placed one on top of the other as shown at 22A and 22B in Figure 2, with (in this case) two flexible longitudinal members 28A,28B positioned between them. The members 28A,28B are so positioned as to ensure that the neutral bending axis of the finished carrier will be at the correct location, as will be described in more detail below with reference to Figures 14 to 21. The two blanks 22A,22B are then secured together so as to hold the members 28A,28B in the correct positions. For example, the blanks 22A,22B may be secured together by soldering or welding, such as in the positions shown by the dots 30. However, they could be secured together in any other suitable way. The third stage in the manufacture of the carrier is shown in Figure 3, where the edge regions 26A,26B are broken or cut off and discarded. In this way, a carrier 12A is produced comprising separate transverse members 32A,32B,32C... interconnected by the flexible longitudinal elements 28A,28B. Each transverse member 32A,32B,32C... is made up of two layers respectively formed from the blanks 22A,22B of Figure 2. In the carrier produced as shown in Figures 4 - 8, items corresponding to those in Figures 1 - 3 are similarly referenced. As shown in Figure 4, a blank 22 is formed with a succession of slits 40, each slit extending completely through the blank 22 but stopping short of the edge regions 26A,26B. As shown in Figures 5 and 6, the slit blank 22 of Figure 4 is then subjected to a thinning-down operation. This thinning-down operation takes place along the length of the blank 22 but is confined to the edge regions 26A,26B. The thinning-down operation may be achieved by passing the blank 22 between the bight of a pair of rollers which are designed to provide a squeezing operation to the material of the blank along the edges 26A,26B but not elsewhere. The effect of the thinning-down operation along the edge regions 26A,26B is to stretch the blank lengthwise so as to convert the slits 40 into slots 42 as shown in Figures 5 and 6. Two blanks 22 of the form shown in Figures 5 and 6 are then placed one on top of the other as shown at 22A,22B in Figure 7, with the flexible longitudinal members 28A,28B being first positioned between them at the desired locations. Again, the blanks 22A,22B are secured together such as in the manner described with reference to Figure 2. The edge regions 26A,26B of each slotted blank are then broken or cut off and discarded as shown in Figure 8. The carrier 12B remains and is of the same general configuration as the carrier 12A of Figure 3. Items in Figures 9 - 13, describing the formation of another form of carrier, items which correspond to items in the preceding Figures are similarly referenced. As shown in Figure 9, a blank 50 is used, the blank 50 being of substantially greater width than the blank 22 of Figures 1 and 4. The blank 50 has a width which is approximately twice the width of the blank 22. Slits 52 are formed in the blank 50, each slit being similar to the slits of Figure 4. Each slit 52 extends through the thickness of the blank 50 but stops short of the longitudinal edge regions 50A,50B of the blank 50. The slit blank 50 is then subjected to a thinning-down operation along its edge regions 50A and 50B, as shown in Figures 10 and 11. This thinning-down operation corresponds to the thinning-down operation described with reference to Figures 5 and 6 and may be carried out in a similar way. The effect of the thinning-down operation is to expand the slits 52 into slots 54. In the next stage of the manufacturing process, the thinned-down blank of the form shown in Figures 10 and 11 is then bent over on itself along a bending line 56 corresponding to the longitudinal line of symmetry of the blank. During this bending operation, the flexible longitudinal members 28A,28B are positioned between the bent-over portions of the blank as shown in Figure 12, the members being positioned in the desired locations. The two superimposed bent-over portions are then secured together in the same way as described with reference to Figure 2 or Figure 8. As shown in Figure 13, the next stage in the procedure is to break off or cut off the superimposed edge regions 50A,50B which are then discarded. A carrier 12C is then formed, which is made up of transverse carrier elements 58A,58B,58C..., each of which comprises superimposed portions of the bent-over blank 50, these carrier elements being interconnected by the flexible longitudinal members 28A, 28B. After the manufacturing stage described with reference to the foregoing Figures, each of the carriers 12A,12B and 12C can be bent into channel-shape, if this is the desired final shape. It may be preferable, however, for this bending into channel-shape to be carried out before removal of the edge regions of the blank. Thus, in the case of the carrier 12A, it could be bent into channel-shape while in the form shown in Figure 2, with the edge regions 26A,26B being thereafter removed. In the case of the channel 12B, it could be bent into channel-shape while in the form shown in Figure 7, with the edge regions 26A,26B thereafter removed. In the case of the carrier 12C, it could be bent into channel-shape while in the form shown in Figure 13, with the edge regions 50A,50B being thereafter removed. After bending into channel-shape, each carrier can then be incorporated into the flexible material 14 of Figure 22. In this way, a carrier can be manufactured with one or more flexible longitudinally extending members 28A,28B, the exact position of the or of each such flexible longitudinal members being easily adjusted during manufacture and then securely fixed in position during the manufacturing stage, as described with reference to Figures 3,7 and 12. Figure 14 shows the end view of a carrier (such as of the form of carrier 12A,12B or 12C), in which there are two flexible longitudinal members 28A,28B, each of these being positioned to run adjacent to the terminal edge of each side wall of the channel, that is, immediately adjacent the channel mouth. Figure 15 shows the bending of such a carrier into an "S" form, and shows how the flexible longitudinal members 28A,28B fix the location of the neutral bending axis to coincide with the plane in which the members 28A,28B lie. Thus, this plane lies substantially on the outside or substantially on the inside of each bend, according to the direction of the bend. Figure 15 illustrates the positions adopted by the carrier elements during bending of the carrier. In practice, of course, the carrier will be embedded in the materal 14. In Figure 15, the mouth of the channel is of course facing in the direction of the arrows A. Figure 16 corresponds to Figure 14, but shows the case where the flexible longitudinal members 28A,28B lie in the side walls of the channel but adjacent to, though just above, the base of the channel. Figure 17 again shows how the members 28A,28B control the position of the neutral bending axis when the carrier is bent through a series of "S" bends so that the neutral bending axis again corresponds to the plane in which the members 28A,28B lie. Therefore, when the carrier is embedded in the flexible material 14, the material more inwardly of each bend than this neutral bending axis will be subjected to compression, while the material more outwardly of this neutral bending axis at each bend will be subjected to tension. In Figure 17, the mouth of the channel of the carrier is of course facing in the direction of the arrows A. In the carrier shown in Figure 18, both of the flexible longitudinal members 28A,28B are incorporated in the same side wall of the channel. Figure 18 shows the configuration adopted by the carrier when it is bent through a series of "S" bends with the mouth of the channel facing into the paper. Therefore, the flexible embedding material 14 (not visible in Figure 19) along the side of the channel of the carrier incorporating the members 28A,28B will be neither compressed nor stretched during bending of the strip in the form shown in Figure 19. However, the remainder of the material 14 will be either stretched or compressed according to the direction of the bends. In the carrier of Figure 20, there is only a single flexible longitudinal member 28, this being incorporated to run along the mid-point of the base of the channel. Figure 21 shows bending of such a carrier when incorporated into the flexible material 14 (not visible in the Figure), with the mouth of the channel of the carrier facing in the direction of the arrows A. The flexible material 14 along the base of the channel will therefore be neither compressed nor stretched through the bends, but the remainder of the material 14 will be stretched or compressed according to the direction of the bends. It will be appreciated that the carriers described enable the sealing, trimming or finishing strips in which they are incorporated (see Figure 22) to be longitudinally compressed. The or each flexible longitudinal member 28 either is itself longitudinally compressible or bends to permit longitudinal compressibility of the strip. This longitudinal compressibility of the strip enables the strip to be made slightly longer than necessary and then compressed to the required length. The positions shown for the flexible longitudinal members 28A,28B (or 28 in the case of Figures 20 and 21) are shown purely by way of example. As illustrated in Figures 1 to 13, the manufacturing methods permit simple adjustment of the position of these members (or member). In certain circumstances, more than two such members may be used.

Claims: A longitudinally extending reinforcing carrier for a flexible longitudinally extending strip (10), including longitudinally extending carrier element means (22A,22B,50) comprising first and second carrier element means (22A,22B) superimposed one on the other, and at least one flexible longitudinal substantially inextensible member (28A,28B) secured to and extending along the carrier element means (22A,22B,50) at a predetermined position relative to its longitudinal axis with the flexible longitudinal substantially inextensible member (28A,28B) clamped between the first and second carrier element means (22A,22B), characterised in that the first carrier element means (22A) comprises a plurality of first separate carrier elements extending side-by-side and parallel to each other and extending widthwise of the carrier, and the second carrier element means (22B) comprises a plurality of second separate carrier elements extending side-by-side and parallel to each other and extending widthwise of the carrier, each first carrier element being superimposed on a respective one of the second carrier elements. A carrier according to claim 1, characterised in that the longitudinal substantially inextensible member (28A,28B) is secured at such predetermined position relative to the longitudinal axis of the carrier that it controls the position of the neutral bending axis in the strip. A carrier according to claim 1 or 2, characterised in that each superimposed pair (58A,58B) of first and second carrier elements comprise respective longitudinally adjacent portions of a thin longitudinally extending blank (50). A carrier according to claim 1,2 or 3, characterised in that each pair (32A,32B,58A,58B...) of superimposed first and second carrier elements is spaced in the longitudinal direction of the carrier from and between the two immediately adjacent pairs thereof. A carrier according to any preceding claim, characterised in that there is a single flexible longitudinal substantially inextensible member (28). A carrier according to claim 5, characterised in that the single flexible longitudinal substantially inextensible member (28) is positioned to coincide with the longitudinal axis of the carrier. A carrier according to any one of claims 1 to 4, characterised in that there are two of the flexible longitudinal substantially inextensible members (28A,28B) arranged on opposite sides of the longitudinal axis of the carrier. A carrier according to claim 7, characterised in that the two flexible longitudinal substantially inextensible members (28A,28B) are disposed symmetrically with reference to the longitudinal axis of the carrier. A carrier according to any preceding claim, characterised in that it is of channel shape. A carrier according to claim 5, characterised in that it has channel shape, and in that the single flexible longitudinal substantially inextensible member (28) lies substantially centrally in the base of the channel. A carrier according to claim 7, characterised in that it has channel shape, and in that the two flexible longitudinal substantially inextensible members (28A, 28B) are positioned one in each side wall of the channel. A carrier according to any one of claims 1 to 4, characterised in that it has channel shape, and in that there are two of the flexible longitudinal substantially inextensible elements (28A,28B), both positioned in the same side wall of the channel. A carrier according to any preceding claim, characterised in that the first and second carrier element means (22A,22B) are secured together by welding. A carrier according to any preceding claim, characterised in that the or each flexible longitudinal substantially inextensible member (28) is a wire or thread. A carrier according to any one of claims 1 to 13, characterised in that the or each flexible longitudinal substantially inextensible member (28) is a metallic wire. A carrier according to any one of claims 1 to 13, characterised in that the or each flexible longitudinal substantially inextensible member (28) is a glass fibre thread. A carrier according to any preceding claim, characterised in that the or each flexible longitudinal substantially inextensible member (28) permits longitudinal compression of the carrier. A longitudinal flexible strip, comprising flexible material and incorporating a carrier, characterised in that the carrier is according to any preceding claim. A strip according claim 18, characterised in that it is in the form of a sealing, trimming, finishing or glass-guiding strip for a motor vehicle body. A strip according to claim 18 or 19, characterised in that the flexible material is plastics or rubber material. A method of manufacturing a reinforcing longitudinally extending carrier for a flexible longitudinally extending strip (10), including the steps of forming longitudinally extending carrier element means (22A,22B,50) by forming first and second substantially identical carrier element means (22A,22B), and securing at least one flexible longitudinal substantially inextensible member (28A,28B) to and extending it along the carrier element means (22A,22B,50) at a predetermined position relative to its longitudinal axis by superimposing one of the carrier element means (22A) on the other (22B) with the flexible longitudinally extending substantially inextensible member (28A,28B) between them, and securing the first and second carrier element means (22A,228) together so as to fix the flexible longitudinal substantially inextensible member (28A,28B) in the predetermined position, characterised in that the first carrier element means (22A) is formed by producing a plurality of separate carrier elements extending side-by-side and parallel to each other and extending widthwise of the carrier, and the second carrier element means (22B) is formed by producing a plurality of separate carrier elements extending side-by-side and parallel to each other and extending widthwise of the carrier, each first carrier element being superimposed as a respective one of the second carrier elements. A method according to claim 21, characterised in that the flexible longitudinal substantially inextensible member (28A,28B) is secured in such predetermined position relative to the longitudinal axis of the carrier that it controls the neutral bending axis of the strip. A method according to claim 21 or 22, characterised in that each carrier element means (22A,22B) is formed by producing side-by-side and parallel slots (42) in a respective thin longitudinally extending blank with the slots (42) extending widthwise of the longitudinal axis of the blank and stopping short of each longitudinal edge region (26A,26B) of the blank, and in that the superimposition step comprises the step of placing one such blank on the other with the slots (42) of the blanks mutually aligned, the longitudinal edge regions (26A,26B) of the blanks being removed and discarded after the securing step. A method according to claim 23, characterised in that the slots (42) are produced in each blank by initially producing side-by-side parallel slits (40) therethrough, each slit (40) stopping short of each longitudinal edge region of the blank, and carrying out a thinning-down operation along the longitudinal edge regions (26A,26B) of each blank whereby to convert each slit (40) into a respective one of the slots (42). A method according to claim 21 or 22, characterised in that the first and second carrier element means comprise respective longitudinally adjacent portions of a thin longitudinally extending blank and are formed by producing side-by-side parallel slots (54) extending widthwise across the blank and across both longitudinal adjacent portions thereof and stopping short of the longitudinally extending edge regions (50A,50B) of the blank, and in that the superimposition step comprises the step of folding one longitudinal adjacent portion onto the other so that one longitudinally extending edge region (50A) is superimposed onto the other (50B), the superimposed longitudinally extending edge regions (50A,50B) being removed and discarded after the securing step. A method according to any one of claims 21 to 25, characterised by the further step of carrying out a bending operation whereby the carrier with the first and second carrier element means (22A,22B), with the or each flexible longitudinally extending substantially inextensible member (28A,28B) between them, is bent into channel-shape. A method of making a longitudinally extending flexible strip, with flexible material in which is embedded a carrier, characterised by the steps of producing a reinforcing carrier according to the method of any one of claims 21 to 26, and embedding the carrier in the strip. A method according to claim 27, characterised in that the embedding step comprises the step of extruding the flexible material over the carrier. A method according to claim 28, characterised in that the flexible material is plastics or rubber material.

Inventors: RICHARD JEAN-PAUL, RICHARD, JEAN-PAUL
Applicants: GENCORP PROPERTY INC, GENCORP PROPERTY INC.
Application year: 1999
Main classification: B60J10
IPC codes: B60J10