Micro-Cellular Foam Weather Seal

Abstract

A weather seal includes an elongated micro-cellular foam bulb, and an elongated micro-cellular foam fin element attached to and extending along the length of the foam bulb. The fin element includes a spine having opposed planar surfaces and at least one microcellular foam barb extending outwardly and at a downward angle from each surface and along the length of the spine. As an alternative to barbs, another option is to use a higher durometer foamed thermoplastic elastomer in a hollow circle shape that would push into a retention pocket. A t-slot version that has a foamed bulb and a polypropylene base is another option.

What is claimed is: 
     
         1 . A weather seal for use on a weather permeable barrier separating the indoor from the outdoor, comprising:
 a. an elongated, compressible micro-cellular foam bulb adapted for connection to the barrier; and   b. an elongated, compressible micro-cellular foam element attached to and extending along the length of the foam bulb, wherein the foam element is spaced from the barrier.   
     
     
         2 . The weather seal according to  claim 1 , further comprising a silicone slip agent incorporated therein. 
     
     
         3 . The weather seal according to  claim 1 , further comprising a polypropylene member attached to and extending the length of the foam bulb and to which the foam element is attached. 
     
     
         4 . The weather seal according to  claim 3 , wherein the polypropylene member comprises an elongated spine attached to the bottom of bulb portion and having opposing surfaces and the foam element comprises at least one barb extending off of each surface of the spine. 
     
     
         5 . The weather seal according to  claim 4 , further comprising a pair of sealing flaps that extend diagonally upward from the top of bulb, opposite the spine. 
     
     
         6 . The weather seal according to  claim 1 , wherein the foam bulb is of a first predetermined diameter and the foam element comprises a bulb-shape and is of a second diameter smaller than the first diameter. 
     
     
         7 . The weather seal according to  claim 1 , wherein the foam bulb is tear-drop shaped and or a predetermined length and the foam element is of a bulb-shape having a diameter that is smaller in dimension than the predetermined length. 
     
     
         8 . The weather seal according to  claim 1 , wherein the bulb has hardness in the range of 10 to 75 durometer on a shore A scale and the foam element has a hardness in the range of 10 to 75 durometer on a shore A scale. 
     
     
         9 . A method for manufacturing a multi-cellular foam weather seal for use on a weather permeable barrier separating the indoor from the outdoor and having an elongated, compressible micro-cellular foam bulb adapted for connection to the barrier and an elongated, compressible micro-cellular foam element attached to and extending along the length of the foam bulb, wherein the foam element is spaced from the barrier, the method comprising the steps of:
 a. delivering the multi-cellular foam material from a storage cell to a weigh scale blender and then to a drier;   b. delivering the multi-cellular foam material from the drier to a main extruder;   c. delivering a polypropylene material from a storage cell to a first co-extruder;   d. pulling the multi-cellular foam material and the polypropylene material from through the main extruder and first co-extruder, respectively, and into a die;   e. forming the weather seal in the die;   f. pulling the weather seal from the die and into a sizer plate;   g. pulling the weather seal from the sizer plate into a cooling tank;   h. blowing off excess water from the weather seal after it passes out of the cooling tank; and   i. winding the weather seal on a reel.   
     
     
         10 . The method according to  claim 8 , comprising the further step of providing a second co-extruder and delivering a slip agent material into the second co-extruder. 
     
     
         11 . The method according to  claim 9 , comprising the further step of injecting the slip agent material from the second c-extruder into the die, whereby the slip agent material will coat the weather strip as it comes out of the die. 
     
     
         12 . The method according to  claim 9 , comprising the further step of optically inspecting the weather strip as it comes out of the cooling tank. 
     
     
         13 . The method according to  claim 9 , comprising the further step of maintaining the water in the cooling tank at a predetermined temperature. 
     
     
         14 . A method for manufacturing a multi-cellular foam weather seal for use on a weather permeable barrier separating the indoor from the outdoor and having an elongated, compressible micro-cellular foam bulb adapted for connection to the barrier and an elongated, compressible micro-cellular foam element attached to and extending along the length of the foam bulb, wherein the foam element is spaced from the barrier, the method comprising the steps of:
 a. preparing a set-up sheet configured with the die tooling parameters, main extruder heat settings, and material recipe;   b. verifying the correct die assembly is in place;   c. verifying the correct material recipe is being used;   d. verify the extruder heat settings are correct;   e. stringing up a weather strip by pulling one through an assembly line to a puller;   f. providing a micro-cellular foaming agent procedure to be followed during manufacture of the weather seal;   g. stabilizing the pressure in the extruders for a predetermined period of time;   h. inspecting the weather strip for quality as it comes off the manufacturing line; and   i. if the weather seal does not pass the quality inspection, adjusting the speed with which the weather strip is pulled through the manufacturing line.