Patent Abstract:
Pile articles ( 20,22 ), especially pile weatherstripping, and a method and apparatus ( 10 ) for making such articles where the backing ( 24 ) and the pile ( 26 ) are of unlike material, especially nylon yarn for the pile ( 26 ) and polypropylene containing material for the backing ( 24 ), wherein prior to the welding of the pile ( 26 ) to the backing ( 24 ) the pile is first pre-heated using ultrasonic energy to melt the pile in a region ( 65 ) thereof where the pile is ultrasonically welded to the backing and before the weld is made. The ultrasonic melting occurs upstream of the location where the pile ( 26 ) is welded to the backing ( 24 ) so that the ultrasonically pre-heated melted region ( 65 ) of the pile ( 26 ) can cool and become at least partially solidified. Then pile ( 26 ) at the pre-heated melted region ( 65 ) is welded to the backing ( 24 ) and causes a reactive or chemical weld to occur, thereby attaching the pile ( 26 ) to the backing ( 24 ).

Full Description:
[0001]    This application claims the benefit of priority to U.S. Provisional Patent Application No. 61/456,240, filed Nov. 3, 2010, which is herein incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to pile weatherstripping and other articles made of a pile of filamentary material, hereinafter referred to as yarn, on a support providing a base or backing of material unlike the yarn and especially a pile exclusively of nylon yarn on a backing which contains polypropylene and having a reactive bond between the backing and the yarn provided by an ultrasonic weld. The invention includes method and apparatus for making such weatherstripping and other articles. 
       BACKGROUND OF THE INVENTION 
       [0003]    Heretofore, pile weatherstripping has been made in large quantities (thousands of feet of weatherstripping per anum) using a process initially developed by Robert Horton (see Horton, U.S. Pat. No. 4,148,953, issued Apr. 10, 1979) where the yarn is helically wound on a traveling band or mandrel, and a backing member of plastic material like the material of the yarn is ultrasonically welded to the yarn along an edge thereof while the yarn and the mandrel move together. The like materials of the yarn and the backing are polypropylene which forms a reactive weld when ultrasonic energy is applied thereto. The following patents also describe the fabrication of pile weatherstripping and also show methods and apparatus for incorporating air and water filtration barrier fins in or along the sides of the pile: Horton, U.S. Pat. No. 4,302,494, issued Nov. 24, 1981; Horton, U.S. Pat. No. 5,060,422, issued Oct. 29, 1991; Johnson et al., U.S. Pat. Nos. 5,338,382, issued Aug. 16, 1994; Johnson, 5,817,390, issued Oct. 6, 1998; and Johnson 5,807,451, issued Sep. 15, 1998. (The patents cited in this paragraph are referenced hereinafter as the “Horton and Johnson patents”). 
         [0004]    It is especially desirable to use nylon for the pile of the weatherstripping because of its wear characteristics and of the ability to absorb crush force as may be applied on the weatherstripping by fenestration products (doors and windows) in which the weatherstripping is installed when such products are forcibly closed. A reactive bond capable of withstanding such forces is especially desirable. It is also desirable to utilize polypropylene in the backing inasmuch as polypropylene is a lower cost material than nylon and provides a competitive advantage in the marketing of the weatherstripping over weatherstripping made entirely of nylon. 
         [0005]    It has been proposed to extrude the backing around the yarn thereby providing a mechanical connection there between, as opposed to a reactive or chemical bond. An extrusion attachment is described in U.S. Pat. No. 5,093,181 to Sanchez, issued Mar. 3, 1992. Interleaved filaments of nylon and polypropylene have also been proposed for providing the pile. Such mixed yarns are mechanically bonded when welded causing the polypropylene to melt and capture the nylon, especially where the polypropylene/nylon yarn is encapsulated in polypropylene to provide the backing for the yarn. Such piles of unlike plastics (Mylar and polypropylene) have been proposed in Ohara et al., U.S. Pat. No. 6,115,566, issued Sep. 5, 2000 and Pawson et al., U.S. Patent Application Publication No. 2009/0258184, published Oct. 15, 2009. 
       SUMMARY OF THE INVENTION 
       [0006]    It is a feature of the present invention to provide pile articles, and a method and apparatus for making pile articles having piles and backings which support the pile of unlike plastic materials, especially piles of a polyamide (e.g., nylon) and backings containing polypropylene (e.g., backing is of polypropylene material, or a composite of materials one of which is polypropylene), where a reactive chemical bond is provided between piles and backings utilizing ultrasonic welding in the manner similar to that of the above-referenced Horton and Johnson patents. 
         [0007]    Briefly described, the invention provides pile articles, especially pile weatherstripping and a method and apparatus for making such articles where the backing and the pile are of unlike material, especially nylon yarn for the pile and polypropylene containing material for the backing, wherein prior to the welding of the yarn of the pile to the backing, the yarn is first pre-heated using ultrasonic energy to melt an area or region thereof where the yarn is to be ultrasonically welded to the backing. The ultrasonic pre-heating occurs upstream of the location where the yarn is welded to the backing so that the melted region of the yarn can cool and become substantially (or at least partially) solidified. The pre-heated melted nylon of the yarn is then welded to the backing and causes a reactive or chemical weld (or bond) to occur. 
         [0008]    Preferably, the backing is a composite of polypropylene and a polyolefin material which is sold under the trade name Plexar (Plexar is an anhydride modified PP typical of suitable tie-layer resins which may be suitable for use in carrying out aspects of the invention) by Equistar Chemicals of Houston, Tex., USA. It is believed that the Plexar polypropylene mixture, which may be 50% Plexar and polypropylene each by weight, is extruded to make the backing. The mixture may be of other percentages of such materials, if desired. It is believed that the reactive bond is a cross-link polymer bond which provides a strong bond. The ultrasonic welding of the backing to the region of the pre-heated, melted and at least partially solidified yarn is achievable using the long-established process of making pile weatherstripping using ultrasonic welding of like yarn and backing material on a traveling band or mandrel, as per the above-identified Horton and Johnson patents. This cross-link bond or weld is capable of withstanding forces, for example in the neighborhood of 40 psi which may occur in the operation of fenestration products equipped with the weatherstripping. If desired, one or more fins may be part of the weatherstripping as in the above-referenced Johnson patents, each of the one or more fins may be made of a polypropylene film or layer, which is heat-bonded to a non-woven nylon layer or flocking, which is deposited on and bonded to the film. 
         [0009]    The invention also provides a method for making a pile article having pile and a backing which supports the pile of unlike plastic material. The method has the steps of heating ultrasonically the pile along an edge thereof to melt a region of the pile prior to welding the pile to the backing, cooling the region to at least partially solidify the melted pile prior to welding the pile to the backing, and then welding ultrasonically the backing to the pile at such region to attach the backing to the pile. Two of the pile articles may be made by repeating the above steps along each of the two edges of pile wrapped around a moving mandrel or band, and then slitting the wrapped pile along the top and bottom of the mandrel or band to separate the two pile articles from each other. 
         [0010]    Further, a pile article is provided having a backing and pile of polymer material which extends from the backing along one side thereof, where the backing is of a material devoid of the polymer material of the pile, and the backing and the pile were ultrasonically welded to each other along at least a partially solidified melted portion of the pile. In other words, a pile of yarn fused to a backing which supports the pile may be exclusively of a first polymer, where the backing contains a second polymer unlike the first polymer. One or more fins may also extend from the backing with the pile in which the portion of the pile when melted included such one or more fins. 
         [0011]    In general, the pile article, of and made using the present invention have a pile of a polyamide material, such as nylon yarn, attached by fusing the pile to a backing of a polymer material. Preferably, the backing material is unlike that of the polyamide material of the pile in that the polymer material of the backing is or contains a polyolefin, such as polypropylene. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The foregoing and other features and advantages of the invention will become more apparent from a reading of the following description in connection with the accompanying drawings in which: 
           [0013]      FIG. 1  is a top view schematically showing an apparatus for making pile weatherstripping utilizing the invention; 
           [0014]      FIG. 2  is a fragmentary perspective view illustrating one of the two pre-heat ultrasonic horns shown in  FIG. 1 ; 
           [0015]      FIG. 3  is a perspective view illustrating one of the pre-heat ultrasonic horns shown in  FIG. 1  with the band having the winding of nylon yarn thereon passing through the groove of the pre-heat horn; 
           [0016]      FIG. 4  is a fragmentary view of a flocked film strip which may optionally be used to provide a fin inside the pile; and 
           [0017]      FIG. 5  is a sectional view illustrating the fin strip around the mandrel passing through the groove in one of the pre-heat ultrasonic horns. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    Referring to  FIG. 1 , there is shown an apparatus  10  similar to that in the above-referenced Johnson and Johnson et al. patents for manufacturing a pair of pile weatherstrips  20  and  22 . Each of the weatherstrips  20  and  22  has a backing of polypropylene blended with Plexar material and extruded into backings  24  from which pile  26  extends. Pile  26  is of polyamide material, preferably nylon yarn. Preferably, the backing may be partially of polypropylene, such as described in more detail later below, but the backing may be entirely or substantially of polypropylene or other non-nylon plastic materials, as desired. The apparatus  10  has a moving band or mandrel  12  of flexible metal guided by rollers  16  along a path in a direction shown by arrow  13 . A winding turret  18  has spools  30  of nylon yarn which winds the yarn helically on the band  12  as it moves through the turret in a downstream direction toward the right as shown in  FIG. 1  to provide wound pile  26 . The turret  18  works in the same way as the winding mechanisms in the above-referenced Horton and Johnson patents. 
         [0019]    In order to assure that the band  12  is moving at constant speed, a sensing “piro” unit  17 , which has a wheel rotating with the band near the upstream end of the path shown in  FIG. 1 , provides a signal to the driver mechanism for driving the band continuously. The speed of the band  12  is therefore made constant and may be synchronized with the rotation of the spools  30  in the turret  18  so that the density of the yarn of the pile  26  in terms of denier and filament count of yarns per inch may be selected. A suitable rate for practicing the invention may be with the band  12  moving at 2.95 inches per second so as to provide a denier of 1125 and a filament count per inch of 40. Other rate, denier, or filament cost may be selected as desired. 
         [0020]    For pile weatherstrip, pile articles of yarn may be twisted nylon filaments. It will be appreciated, of course, that the pile  26  may be made of nylon monofilaments rather than twisted material. In either case, the term yarn refers to the threads, filaments or twisted threads which are wound on the band  12 . The backings  24  are directed from reels in which the strips constituting the backings are wound and are not shown in  FIG. 1 . The backings  24  are guided by pairs of guide rollers  32  and  34  to ultrasonic welding stations  40  and  42  which are spaced from each other along the path of travel of the band  12 . Each station  40  and  42  includes an ultrasonic horn (or head)  50  disposed against first and second fixtures  52 , respectively, which are held against the horn and provide backing  24  for the band  12  so as to facilitate welding by the horns  50  of the backings  24  and the wound pile  26  to each other. The operation of the welding stations  40  and  42  is as described in the above-identified Horton and Johnson patents, which are incorporated herein by reference. For example, the horns  50  may be driven by their drivers at approximately 20 kHz and served to melt both the yarn of pile  26  and the backings  24  so as to provide a fused region wherein there is a reactive or chemical bond, which is believed to include chemical cross-linking of the polymers in the backing and in the yarn, even though they are not of like material. After welding stations  40  and  42 , the pile  26  is cut from band  12  into separate weatherstrips  20  and  22  by a slitter unit  66  shown at the downstream end of the apparatus in  FIG. 1 , which provides two wheels with cutting edges disposed above and the other below band  12  to slit pile  26 . For example, pile  26  may be of a height of ¼ inch, and ½ inch wide around band  12  until the two weatherstrips  20  and  22  are cut from band  12  by slitter unit  66 . 
         [0021]    It has been found desirable to provide a composite backing material of PX 6006 anhydride modified polypropylene, which is sold under the trade name Plexar by Equistar Chemicals of Houston, Tex., USA. The PX 6006 and the polymer are separate resins which are mixed, suitably in a 50/50 ratio by weight. The resins of the backing are mixed and fed into an extruder wherein they are extruded into sheets which may be cut into strips providing the backings  24 . Polypropylene is thus one of the resins forming the backing material, but other proportions or percentages in the mixture of resins than set forth above may be used, if desired. 
         [0022]    Ordinarily the unlike or dissimilar plastic materials, namely polypropylene and nylon will not fuse or weld even if heated ultrasonically by the ultrasonic horns  50  in stations  40  and  42 . In other words, the polymers providing the pile and backing do not bond when welded by melting under pressure, which would otherwise be possible if they each were of a common polymer material, such as nylon. According to the present invention, it has been discovered that heating the edges of the yarn pile  26  while wound on the band  20  ultrasonically with pre-heat horns  60 , which may be driven by ultrasonic vibrators or drivers  62  at the same rate as the conventional horns  50  (e.g., 20 kHz) along the edges of the band  12  solves this problem. The pre-heating horns  60  fuses the wound yarn pile  26  in region (area or portion) of the yarn pile which will be ultrasonically welded in ultrasonic welding stations  40  and  42  to backings  24 . Then, the ultrasonic welding in the stations  40  and  42  provides reactive or chemical bonding between the yarn pile  26  and the backings  24 , capable of withstanding forces in opening and closing of windows or otherwise in fenestration products. It is found that the pre-heat horns  60  should be disposed upstream of horns  50  in the stations  40  and  42  by a distance for sufficiently cooling of the yarn pre-heated so as to allow the melted edges along a region of the yarn pre-heated by horns  60  to solidify, at least partially. The distance for cooling depends upon the speed of the band  12  and the density of the yarn as it is wound around the band  12 . 
         [0023]    As shown in  FIGS. 2 and 3 , the pre-heat horns  60  are formed with grooves  64  which are sufficiently deep to encompass a region  65  about the edges of the yarn wound around the band  12 . The melted and then at least partially solidify pile region  65  represents the portion of the yarn pile  26  which faced groove  64  when passing there through, i.e., region  65  is the yarn wound along one of the two opposite sides about the width of band  12  and extending partially along upon the upper and lower surface of the band according to the depth of groove  64 . For example, the groove  64  of each horn may be approximately ⅛ inch in depth, and generally semi-circular at least at the bottom thereof, where pile  26  is of height of ¼ inch, and ½ inch wide around band  12 . 
         [0024]    It may be desirable to provide a fin  70  in the weatherstrips. Preferably, the fin  70  includes a strip of polypropylene film material (or layer)  70   a  bonded using heat and a suitable bonding material, such as the Plexar mentioned above, to a flocked or non-woven nylon layer  70   b , such as shown in  FIG. 4 . The nylon layer  70   b  and the film  70   a  providing fin  70  are disposed inside the pile  26  wound on the band  12  and are welded both preliminarily by the pre-heat horns  60  and then by horns  50  providing reactive welds between the nylon material of the pile  26 , the polypropylene film  70   a  of fin  70 , and the nylon layer  70   b  of fin  70 . The fin&#39;s nylon layer  70   b  along yarn region  65  is pre-heated along with the yarn in grooves  64  of horns  60  and thereby melts and fuses with the yarn, cools to at least partially solidify, and then horns  50  bond the melted fused fin and yarn to the backings  24 . Accordingly, a fin  70  having wearability in use in fenestration products like the nylon yarn of the pile  26  is provided.  FIG. 5  shows the location of the fin  70  with the flocking thereon in a groove  64  of one of the pre-heat horns  60 . For purposes of illustration,  FIG. 5  shows an example fin  70  only along one of the two opposite sides of band  12  in pile  26 , but the bonded layered materials providing fin may extend (along the top of band  12  shown) to similarly wrap around the other side of the band  12  such that each pile article  20  and  22  when cut has a fin. 
         [0025]    When the pile wrapped around the band  12  arrives on the moving band  12  at ultrasonic welding stations  40  and  42 , the pile regions melted by horns  60  although cooled may still be at an elevated temperature than if horns  60  were not provided. Horns  50  also melt the yarn of pile  26  at least including (or substantially including) the pile region melted earlier by horns  60  thereby attaching backing  24  by reactively or chemically bonding the pile to the backing. Thus, as melting takes place at both horns  50  and horns  60 , then along each side of band  12  its respective horn  60  pre-melts or fuses a region of the pile before such region is further melted or fused at horn  50  when the backing is applied and bonded. The pile  26  of each pile article made, such as weatherstrips  20  and  22 , are composed of multiple partial loops of yarn each having a bottom and two sections extending there from to two free ends, respectively, in a direction away from backing  24  along one side of the backing. The improvement over the Horton and Johnson patent is that when unlike polymer (e.g., plastic) materials are used for the pile and backing, the bottom of the loop and a portion of each of its two sections extending there from are welded to the backing at stations  40  and  42  after being pre-heated as described above by horns  60  to enable the desired bonding of the pile and backing, with or without one or more fins. Since the backing has polypropylene, this reduces the overall cost of the pile articles than if the backing were of nylon, as polypropylene is a lower cost material than nylon. 
         [0026]    From the foregoing description, it will be apparent that there has been provided methods and apparatus for fabricating weatherstripping and other pile articles, such as brushes, having dissimilar materials in the pile and in the backings (or support or base) of the article. Variations and modifications of the herein described method and apparatus within the scope of the invention will undoubtedly suggest themselves to those skilled in the art. Accordingly, the foregoing description should be taken as illustrative and not in a limiting sense.

Technology Classification (CPC): 1