Method of manufacturing a material strand

Abstract

A method of manufacturing a material strand (100), particularly for sealing, trimming or fastening of doors (11) or windows (12) of a motor vehicle (10), comprises the steps of: a) extrusion of an extruded strand (200); b) testing the extruded strand (200) after the extrusion, thereby identifying first segments (210) comprising manufacturing defects (211) and second segments (220) being free from manufacturing detects; c) cutting out the first segments (210) from the extruded strand (200), thereby causing faces (222) at the second segments (220); d) joining cut faces (222) of second segments (220) to obtain a joint (102) and to form a material strand (100), the joint (102) having a position within the material strand (100), wherein a minimum distance (d) is maintained between the positions of adjacent joints (102); e) identifying the position of each joint (102); and f) forming a transport unit (110) having a predetermined maximum length by winding the material strand (100).

Claims

1. A method of manufacturing a material strand for sealing, trimming or fastening of doors or windows of a motor vehicle, the method comprising the steps of: a) extrusion of an extruded strand; b) prior to forming a transport unit, testing the extruded strand after the extrusion, thereby identifying first segments comprising manufacturing defects and second segments being free from manufacturing defects; c) prior to forming the transport unit, cutting out the first segments from the extruded strand, thereby causing cut faces at the second segments; d) prior to forming the transport unit, cutting out the second segments from the extruded strand which have a length less than a predetermined minimum distance (d), the minimum distance (d) being long enough to form a sealing strip or a trim strip; e) prior to forming the transport unit, joining cut faces of second segments which have a length equal to or longer than the minimum distance (d) to obtain a joint and to form a material strand, the joint having a position within the material strand, wherein the minimum distance (d) is maintained between the positions of adjacent joints; f) prior to forming the transport unit, identifying the position of each joint; and g) forming the transport unit having a predetermined maximum length by winding the material strand.

2. The method according to claim 1, wherein the extruded strand is conveyed along a conveying direction (C), wherein in step b), the extruded strand is tested at a testing position along the conveying direction (C).

3. The method according to claim 2, wherein in step c), the first segments are cut out at a stamping position, the stamping position being arranged along the conveying direction (C) behind the testing position.

4. The method according to claim 3, wherein in step c), the first segments are cut out by stamping, wherein a first stamping is performed prior to a first segment passing the stamping position and a second stamping is performed after the first segment has passed the stamping position.

5. The method according to claim 3, wherein the cut faces to be joined in step e) are formed so as to have complementary shapes.

6. The method according to claim 3, wherein the minimum distance (d) is between about 5 m and about 15 m.

7. The method according to claim 2, wherein in step g), the transport unit of the material strand is formed by winding the material strand onto a reel.

8. The method according to claim 1, wherein the cut faces to be joined in step e) are formed so as to have complementary shapes.

9. The method according to claim 8, wherein the cut faces have a stepped shape.

10. The method according to claim 8, wherein in step e), the second segments are joined by welding or sewing or adhering.

11. The method according to claim 8, wherein in step f), the position of each joint is identified by storing the position.

12. The method according to claim 1, wherein in step e), the second segments are joined by welding or sewing or adhering.

13. The method according to claim 1, wherein in step f), the position of each joint is identified by at least one of: a metal marker disposed at or near the cut faces of the joint, a paint applied at or near the cut faces of the joint, a radiocommunication member disposed at or near the cut faces of the joint, and a plastic marker disposed at or near the cut faces of the joint or by a metal seam.

14. The method according to claim 1, wherein in step f), the position of each joint is identified by storing the position, and wherein the position is stored on a data storage medium.

15. The method according to claim 1, wherein in step g), the transport unit of the material strand is formed by winding the material strand onto a reel.

16. The method according to claim 1, wherein the minimum distance (d) is between about 5 m and about 15 m.

17. The method according to claim 16, wherein the minimum distance (d) is between about 8 m and about 12 m.

18. The method according to claim 1, wherein the maximum length is between about 800 m and about 2000 m.

19. The method according to claim 18, wherein the maximum length is between about 1000 m and about 1600 m.

20. The method according to claim 18, wherein the maximum length is about 1400 m.

Description

(1) In the following, the invention will be described in detail with reference to preferred embodiments, wherein:

(2) FIG. 1 shows an automotive vehicle with sealing strips manufactured in accordance with the method described herein;

(3) FIG. 2 represents a graphical illustration of the method sequence;

(4) FIG. 3 is a side view of an arbitrary part of an extruded strand having manufacturing defects;

(5) FIG. 4 is a side view of the arbitrary part of an extruded strand from FIG. 3, wherein the first segment is cut out from the extruded strand;

(6) FIG. 5 is a side view of an arbitrary part of a material strand having a joint;

(7) FIG. 6 is a cross-sectional view of the profile strand and

(8) FIG. 7 is a cross-sectional view of the profile strand, wherein the hollow chamber is folded open.

(9) Referring now to FIG. 1, it is shown an automotive vehicle 10. The automotive vehicle 10 has, at its doors and windows, sealing strips 120 and trim strips 121 that may be cut out from a material strand manufactured according to the method described herein. However, it is possible to manufacture most different types of material strands in accordance with the invention which do not necessarily have to find appliance in automotive industry.

(10) FIG. 2 shows a graphical illustration of the method's sequence when cutting out the first segments 210 from the extruded strand 200. The first segments 210 are those segments of the extruded strand 200 that comprise manufacturing defects 211 whereas the second segments 220 are free from manufacturing defects 211.

(11) A manufacturing defect 211 may be any defect of the extruded strand 200 that occurs during manufacture of the extruded strand 200, particularly an extrusion defect. Manufacturing defects 211 usually lead to functional and/or optical impairments. Therefore, sealing or trim strips 120, 121 comprising manufacturing defects 211 must not be applied to windows or doors. As was mentioned before, joints 102 are not considered to be manufacturing defects 211 for the purpose of the present invention.

(12) As can be seen in FIG. 2, a manufacture environment 300 comprises a testing position 301 and a stamping position 302. An extruded strand 200 is conveyed in the manufacture environment 300 along a conveying direction C. The stamping position 302 is arranged along the conveying direction C behind the testing position 301. Hence, the extruded strand 200 is tested first to detect possible manufacturing defects 211 before it reaches the stamping position 302.

(13) In FIG. 2, condition (1), the extruded strand 200 comprises second segments 220 and a first segment 210, the first segment 210 comprising manufacturing defects 211. In condition (1), the first segment 210 with manufacturing defects 211 is just passing the testing position 301, and the manufacturing defects 211 are detected at the testing position 301.

(14) In condition (2), the extruded strand 200 has been further conveyed along the conveying direction C so that the first segment 210 is about to pass the stamping position 302. At this time, a first stamping is performed so as to separate the first segment 210 comprising the manufacturing defects 211 from the preceding second segment 220.

(15) In condition (3), the first segment 210 comprising the manufacturing defects 211 is also separated from the succeeding second segment 220 as a second stamping is performed shortly after the first segment 210 has passed the stamping position 302. Hence, the first segment 210 is cut out from the extruded strand 200 and can be wasted or recycled. By performing the stamping actions, cut faces 222 remain at the second segments 220 and also at the first segment 210.

(16) In condition (3), it is apparent that the segment following the first segment 210 in the conveying direction C, hereafter referred to as the succeeding segment, consists of a second segment 220 followed by a first segment 210 comprising manufacturing defects 211. It is also apparent that the distance between the cut face 222 of the succeeding segment and the first segment 210 is less than the minimum distance d that is to be maintained between the positions of adjacent joints 102. Put differently, the second segment 220 of the succeeding segment is too short to form a sealing strip or a trim strip.

(17) Therefore, in condition (4), the second segment 220 is again cut out from the extruded strand 200 as soon as the first segment 210 has passed the stamping position 302. Again, the first segment 210 can be wasted or recycled.

(18) As can be seen in condition (5), the succeeding second segment 220 is longer than the minimum distance d that is to be maintained between the positions of adjacent joints 102. It is shown that the two second segments 220 that are free from manufacturing defects are joined to form a material strand 100.

(19) In other possible configurations, the manufacture environment can include more than one stamping position 302 for performing the first and second stampings and/or the stamping position 302 is variable, i. e. the stamping means is capable of changing its position along the conveying direction C.

(20) By the method's sequence described in FIG. 2, the material waste can be considerably reduced due to the fact that there is no need to waste entire strips, if they comprise manufacturing defects, but the length of those segments comprising manufacturing defects that are cut out and wasted varies with the occurrence of manufacturing defects. In most cases, only a short segment will need to be cut out from the extruded strand 200. It is only necessary in few cases, namely if the distance between a cut face 212 and the next manufacturing defect is less than the minimum distance d between adjacent joints 102, to cut out a longer part from the extruded strand 200.

(21) FIGS. 3 to 5 show side views of extruded strands 200 or material strand 100, depending on the stage of the method. In FIG. 3, an arbitrary part of an extruded strand 200 is shown. The part of the extruded strand 200 consists of a first segment 210 and of second segments 220. The first segment 210 comprises manufacturing defects 211, whereas the second segments 220 are free from manufacturing defects.

(22) Referring now to FIG. 4, it is shown the arbitrary part of an extruded strand 200 from FIG. 3. In the meantime, the first segment 210 has been cut out from the extruded strand 200. By cutting out the first segment 210 from the extruded strand 200, the second segments 220 as well as the first segment 210 have obtained cut faces 212, 222 at the respective cutting points.

(23) As is evident from FIG. 4, the cut faces 212, 222 have complementary shapes. In the present embodiment shown in FIG. 4, they have stepped shapes so as to ensure a corresponding orientation around the strand's longitudinal axis L. However, the shape of the cut faces 212, 222 can also be, for example, oblique, convex, or concave. The first segment 210 cut out from the extruded strand 200 can be wasted or recycled in any way, if applicable.

(24) FIG. 5 shows an arbitrary part of a material strand 100 after joining two second segments 220. The two second segments 220 are joined with each other via a joint 102. In the present exemplary embodiment, the second segments 220 are sewn to one another. However, the joint 102 can also be produced in most different other ways, such as adhering or welding. In this exemplary embodiment, the cut faces 222 of the second segments 220 are oblique to the longitudinal axis L of the material strand 100.

(25) In FIG. 5 it is shown that a metal marker 103 is interposed between the two second segments 220. The metal marker 103 serves as an identification means so that the position of a joint 102 can easily be identified when processing the material strand. For example, the position of the metal marker 103 can be identified by a metal detector. In another possible configuration, the seam forming the joint 102 between second segments 220 is made of metal so that the seam fulfils both the function of joining the second segments 220 and the function of identifying the joint 102 at the same time.

(26) It is also possible to choose other types of identification means. For example, the joint 102 can be identified visually by applying a paint at or near the joint 102. Also, a radiocommunication member, such as a Near Field Communication-chip (NFC-chip) may be disposed at or near the joint 102 so as to be readable by a radiocommunication device.

(27) In FIG. 5, the identification means, i. e. the metal marker 103, is interposed between the two second segments 220 before joining them. However, the identification means can also be disposed close to the joint 102 of the second segments 220, but not therebetween.

(28) Referring now to FIG. 6, it is shown a cross-sectional view of the material strand 100. The material strand 100 comprises a function portion and a fastening portion 105. The function portion is a hollow chamber 104. The fastening portion 105 is configured to receive a flange of the door 11 or the window 12 of the automotive vehicle 10. With regard to a detailed description of the fastening portion's 105 functionality, it is referred to DE 10 2006 060 391 C5.

(29) In FIG. 7, there is shown a transport unit 110 comprising a plurality of receiving devices 112, 113, 114, 115. Each of the receiving devices 112, 113, 114, 115 has a reel 111 and each reel 111 extends in a vertical direction V. Each receiving device 112, 113, 114, 115 is configured to receive a material strand 100 around the reel 111 so that the material strand 100 can be wound around a vertical axis. The receiving devices 112, 113, 114, 115 are stackable one onto another, as is shown in FIG. 7. This ensures that the transport of the material strand 100 is space-saving and inexpensive.

(30) A transport unit 110 can comprise a single receiving device 112, 113, 114, 115, or it can comprise a plurality of receiving devices 112, 113, 114, 115 stacked onto one another. If the transport unit 110 comprises a plurality of receiving devices 112, 113, 114, 115, the material strand 100 can be continuously wound around the reels 111 of more than only one receiving device 112, 113, 114, 115 without there being a need to disconnect the material strand 100. In other configurations, the reel 111 can extend in a horizontal direction so that the material strand 100 is wound around a horizontal axis.

LIST OF REFERENCE SIGNS

(31) TABLE-US-00001 10 motor vehicle 11 door 12 window 100 material strand 102 joint 103 metal marker 104 hollow chamber 105 fastening portion 110 transport unit 111 reel 112 receiving device 113 receiving device 114 receiving device 115 receiving device 120 sealing strip 121 trim strip 200 extruded strand 210 first segment 211 manufacturing defect 212 cut face 220 second segment 222 cut face 300 manufacture environment 301 testing position 302 stamping position d minimum distance C conveying direction L longitudinal axis V vertical direction