Process for fabricating weatherseals

Abstract

A process for forming linear, thermoplastic weatherseals into a bend position is provided which avoids buckling of the thinner surfaces of the weatherseal material. The process involves the use of a support insert which supports the thinner surfaces during the bending operation, and thus assists in preventing the deformation of the thinner weatherseal surfaces. The support is preferable constructed of a material which is unaffected by temperatures higher than the heat-deformation temperature used to set the weatherseal material into a bent configuration, and thus, the support insert retains its linear shape when removed from the bending press, and therefore, can be reused. An improved process for manufacturing bent thermoplastic weatherseal material results.

1 . A process for forming thermoplastic weatherseals into a bent condition comprising: 
 a) inserting a bendable support insert into at least a portion of a linear, straight thermoplastic weatherseal material to provide a bendable weatherseal assembly;    b) inserting said bendable weatherseal assembly into a bending press, and activating said press in order to bend said weatherseal assembly into a bent position;    c) heating said weatherseal assembly in said bent position to a bending temperature greater than the heat deformation temperature of said thermoplastic material;    d) maintaining said assembly in said press until said thermoplastic material is set into said bent condition; and    e) removing said weatherseal assembly from said press, and removing said support insert from said thermoplastic weatherseal material, wherein,    said thermoplastic weatherseal material essentially maintains said bent condition when removed from said press.    
   
   
       2 . A process as claimed in  claim 1  wherein said linear, straight thermoplastic weatherseal material is extruded.  
   
   
       3 . A process as claimed in  claim 1  wherein said thermoplastic weatherseal material is TPV.  
   
   
       4 . A process as claimed in  claim 1  wherein said support insert is manufactured from a silicon based material.  
   
   
       5 . A process as claimed in  claim 1  wherein said heat deformation temperature is greater than 120° C.  
   
   
       6 . A process as claimed in  claim 1  wherein said support insert is essentially unaffected by heating to said bending temperature.  
   
   
       7 . A process as claimed in  claim 1  wherein said weatherseal assembly is bent to an angle of between 20° to 180°.  
   
   
       8 . A process as claimed in  claim 1  wherein said weatherseal material has, in cross section, thin sections which are supported by the surfaces of said support insert.  
   
   
       9 . A support insert for use in the operation of forming thermoplastic weatherseals into a bent position comprising a base structure manufactured of a flexible material, having at least one face of which corresponds to the surface of said weatherseal, so as to support said weatherseal during a bending process, and wherein said flexible material is essentially non-reactive with said weatherseal.  
   
   
       10 . A support insert as claimed in  claim 9 , wherein said flexible material is a silicone based material.  
   
   
       11 . A TPV weatherseal which has been formed to a bent condition using the process of  claim 1.