Weather strip, manufacturing method thereof and molding device

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a weather strip having a molded part, a manufacturing method thereof and a molding device.

2. Related Art

Conventionally, when manufacturing weather strips having a hollow portion of this type, an extruded part having the hollow portion is formed into an elongated shape through a known extrusion process. Then, the extruded part is cut to a predetermined length so as to form the extruded part with the predetermined length, and at least one distal end portion of the extruded part so formed is then set in a molding device for molding a molded part, whereby the molded part is molded so as to be continuously connected to the end portion of the extruded part.

The molding device that is used for the connection molding of the molded part is provided with a stationary mold, a plurality of movable molds and a core mold. The core mold is provided with a core main body and an extending plate which extends from the core main body for forming a hollow portion of the molded part. When molding the molded part, firstly, such that the respective molds are opened, at least one end portion of the extruded part with the predetermined length is set such that the end portion of the extruded part is fitted on one end portion of the core main body and another end portion of the extruded part is fitted on anther end portion of the core main body, and both end portions of the extruded parts are mounted in the molding device. Next, the respective molds are arranged at predetermined positions and are then closed together. At this time, a cavity for molding the molded part is formed by the respective molds and the extruded parts. Then, an unvulcanized rubber is injected into the cavity via a gate, not shown, so as to fill the cavity with the same rubber. Thereafter, the unvulcanized rubber is vulcanized, and the respective molds are opened so as to take out the core mold and the vulcanized rubber (a molded part precursor) which are integrated with each other. As this occurs, a slit will be formed in the precursor due to the existence of the extending plate.

Then, the molded part precursor having the hollow portion can be obtained by taking out the core main body from the slit. Thereafter, opening surfaces of the slit which face each other are joined together at a plurality of locations with an adhesive to thereby obtain the molded part. Namely, a weather strip can be obtained in which the molded part is integrated with the extruded part (refer to, for example, Japanese patent publication No. JP-A-058-205749).

Incidentally, when attempting to form a hollow portion over the whole area of the molded part in a longitudinal direction thereof, a core main body is proved so as to extend over the whole area of the molded part in the longitudinal direction thereof. In view of the easy removal of the core main body, it is desirable to form a slit so as to also extend over substantially the whole area of the molded part in the longitudinal direction thereof.

In this case, however, since the slit becomes long, the slit needs to be bonded at many locations therealong after the core main body has been removed. As a result, there may be caused a risk that increases in working manhours and cost are called for.

In addition, since the slit is bonded to be closed, the molded part is forced to be deformed in a direction in which its width is reduced. By this configuration, the product and the molds need to be designed allowing for such a deformation, this calling for a risk that the design becomes complex and the number of manhours required for design increases.

Furthermore, when molding the molded part which corresponds to a corner part, in the event that an inner angle of the corner part is relatively small (for example, less than 100 degrees), there is imposed a limitation that the width of the extending plate has to be narrowed. Even in this case, however, there exist needs of the implementation of effortless molding.

SUMMARY OF THE INVENTION

The invention was made with a view to solving the problem, and an object thereof is to provide a weather strip, a manufacturing method thereof and a molding device which can suppress increases in working and designing manhours and costs and realize a remarkable improvement in workability in molding and post machining after molding, when manufacturing the weather strip having the molded part.

Hereinafter, some aspects of the invention appropriate to attain the object will be described item by item.

(1) A weather strip including a molded part, corresponding to a corner portion of the weather strip, having a base portion and a seal portion which protrudes from the base portion so as to define a hollow portion, wherein

a first slit and a second slit are formed in the base portion of the molded part so as to extend along a longitudinal direction for removal of a core mold and a bridge portion is formed integrally with the base portion between the first and second slits, and wherein the second slit is formed so as to extend through an inner corner portion.

According to (1), the bridge portion is integrally formed with the base portion between the two longitudinally extending slits formed for ease of the removal of the core mold. By this configuration, being different from the related art in which a slit portion needs to be bonded to be closed after molding, no bonding is required by virtue of the bridge portion. In addition, in designing, no allowance needs to be made for an extent of deformation that would otherwise be caused in association with closure of the slit portion. Consequently, it is possible to realize the suppression of increases in designing and working manhours and costs. Furthermore, since the slits are formed in the base portion, being different from a case where slits are formed in the seal portion, it is possible to prevent the occurrence of a risk that the rigidity of the seal portion is damaged by the slits to thereby reduce the sealing properties.

Moreover, since the two slits are formed, only the two extending plates are required which make up the core mold and form the slits, and no wide space needs to be provided between both the plates. Here, when molding the molded part which corresponds to the corner part, in the event that the inner angle of the corner part is relatively small, there is imposed a limitation that the width of the extending plates has to be narrowed. Even in the event that such is the case, the width of the extending plates can be limited to a minimum width without expanding the space between the two extending plates. As a result, there is provided an advantage that a stable molding is ensured without placing a load on the molding device.

According to (1), the second slit is formed so as to extend through the inner corner portion. Consequently, first of all, one of the extending plates which is situated at a second slit side of the core mold is removed, whereby the second slit opens in an intersecting direction (in an L-shape). By this configuration, removal work of the remaining core mold can be implemented relatively easily. In this respect, it is possible to remarkably improve the workability in manufacturing.

(2) A manufacturing method of a weather strip having a molded part comprising a base portion and a seal portion which protrudes from the base portion so as to define a hollow portion, comprising the steps of:

forming a cavity by a molding device provided with at least a core mold for forming the hollow portion and a sliding mold that is slidable relative to the core mold;

injecting an elastic material which is in a plasticized state into the cavity, so as to fill the cavity with the elastic material, and then setting the elastic material,

forming a bridge portion integrally with the base portion between the first and second slits; and

opening the molding device so as to remove the core mold from the first slit and the second slit to thereby obtain the molded part in which the hollow portion is molded; wherein the core mold includes:

a first core having a first core main body and a first extending plate which extends from the first core main body; and

a second core continuously connected to an end of the first core main body which constitutes a longitudinal end of a weather strip and having a second core main body and a second extending plate which extends from the second core main body; and

the sliding mold includes:

a first projection which is to be contacted with the first core main body at a second core side of the first extending plate; and

a second projection which is to be contacted with the second main body or the first core main body at a fist core side of the second extending plate;

wherein the first slit is formed by the first extending plate and the first projection for removal of the first core main body; and

the second slit is formed by the second projection and the second extending plate for removal of the second core main body;

whereby when removing the core mold, the sliding mold is caused to slide to move in a direction in which the first extending plate and the second extending plate extend such that the first projection and the second projection are separated relatively from the first core main body and the second core main body, respectively, so that the first core main body and the second core main body are removed from the first slit and the second slit, respectively.

According to (2), since the bridge portion is formed integrally with the base portion between the first and second slits which extend in the longitudinal direction for ease of the removal of the core mold, being different from the related art in which a slit portion needs to be bonded to be closed after molding, no bonding is required by virtue of the integral bridge portion. In addition, in designing, no allowance needs to be made for an extent of deformation that would otherwise be caused in association with closure of the slit portion. Consequently, it is possible to realize the suppression of increases in designing and working manhours and costs. Furthermore, since the slits are formed in the seal portion for removing the core mold therefrom, being different from a case where slits are formed in the base portion, it is possible to prevent the occurrence of a risk that the rigidity of the seal portion is damaged by the slits to thereby reduce the sealing properties.

In addition, the core mold that is used for molding the hollow portion includes the first core and the second core, and the sliding mold includes at least the first projection which is to be contacted with the first core main body at the second core side of the first extending plate and the second projection which is to be contacted with the second main body or the first core main body at the fist core side of the second extending plate. Then, when removing the core mold, the first and second projections are separated relatively from the first core main body and the second core main body, respectively, by sliding the sliding mold along the extending direction of the first extending plate and the second extending plate. Then, the first projection and the second projection are removed, whereby openings, which constitute part of the slits, are formed in the second core side of the first extending plate and the first core side of the second extending plate. By this configuration, a molded body can be moved relatively to the first core main body and the second core main body, whereby one of the core main bodies can be removed from one of the slits by virtue of the relative movement. Then, when the remaining core main body is removed from the other slit, the core mold can easily be removed. In other words, a remarkable improved can be realized in workability during manufacturing without calling for a complicated construction and placing a load on the mold. In addition, only the two extending plates are required to form both the slits, and the space between the two slits does not have to be expanded widely. Here, when attempting to mold the molded part which corresponds to the corner part, in the event that the inner angle of the corner part is relatively small, there is imposed a limitation that the width of the extending plates has to be narrowed. Even in the event that such is the case, the width of the extending plates can be limited to a minimum width without expanding the space between the two extending plates.

(3) A molding device of a weather strip, comprising:

a core mold and a sliding mold which is provided slidably relative to the core mold for forming a molded part of the weather strip which comprises a base portion and a seal portion which protrudes from the base portion so as to form a hollow portion,

wherein

the core mold includes:

a first core having a first core main body and a first extending plate which extends from the first core main body for forming the hollow portion; and

the sliding mold includes:

a first projection which is to be contacted with the first core main body such that the first projection is brought in a close contact with a second core side of the first extending plate; and

a second projection which is to be contacted with the first main body or the second core main body such that the second projection is brought in a close contact with a fist core side of the second extending plate.

According to (3), basically, the same function and advantage as those provided by (2) are provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view which describes a molded part as viewed from an attaching surface side of a weather strip in an embodiment;

FIG. 2 is an exemplary drawing which briefly describes the construction of the weather strip;

FIG. 3 is a sectional view which illustrates an example of an extruded part;

FIG. 4 is a sectional view which illustrates a molded part which corresponds to an upper corner part;

FIG. 5 is a partial sectional view as viewed in a lateral direction which illustrates a molding device for use for molding the molded part;

FIGS. 6A and 6B are partial sectional views in a vertical direction which illustrate the molding device;

FIG. 7 is an exemplary drawing of the molding device and the like which describes a molding process of the molded part;

FIG. 8 is an exemplary drawing of the molding device and the like which describes the molding process of the molded part;

FIG. 9 is an exemplary drawing of the molding device and the like which describes the molding process of the molded part; and

FIG. 10 is an exemplary drawing of the molding device and the like which describes the molding process of the molded part.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, one embodiment of the invention will be described by reference to the drawings. As shown in FIG. 2, a door weather strip (hereinafter, simply referred to as a weather strip) 1 of EPDM (ethylene-propylene-diene terpolymer) or TPO (thermoplastic elastomer of olefin) is attached so as to extend along an outer peripheral portion thereof, for example, to an automotive door.

The weather strip 1 includes extruded parts 2, 3 and molded parts (portions to which a dot-scattering pattern is imparted in the figure) 4, 5. Namely, extruded parts which are formed substantially in a straight line (into an elongated shape) by means of an extruding machine, not shown, and are then cut to predetermined lengths are used for the extruded parts 2, 3. In addition, the molded parts 4, 5 are formed or molded by means of a predetermined molding device so as to connect together end edges of the adjacent extruded parts 2, 3.

As shown in FIG. 3, the extruded part 2(,3) includes a base portion 11 which is attached to a door frame of an automotive door, not shown, a seal portion 13 which extends from the base portion 11 and has a hollow portion 12 therein and a lip portion 14 which extends from a proximal end portion of the seal portion 13.

In addition, as shown in FIG. 4, as to the molded part 4 (,5), while shapes are slightly different, as with the extruded parts 2, 3, the molded part has a base portion 21, a hollow portion 22, a seal portion 23 and a lip portion 24. As shown in FIG. 1, in this embodiment, since the molded part 4 which corresponds to an upper corner part has specific features to the embodiment, the description of the embodiment will be made hereinafter mainly with respect to the molded part 4. Note that in FIG. 1, as a matter of convenience in description, a weather strip is shown which is to be attached to a door at the side of a front passenger seat. As shown in the same figure, the molded part 4 in this embodiment is formed into substantially an L-shape so as to correspond to the upper corner part, and an upper side portion (a lateral portion) constitutes a shorter side portion and a vertical portion constitutes a longer side portion, an inner angle of the molded part 4 being set to less than 100 degrees, for example, 95 degrees. Then, in the molded part 4 in this embodiment, a slit 30 is formed in the base portion 21 thereof for ease of the removal of a core mold, which will be described later on.

The slit 30 includes a first slit 31 and a second slit 32. Both the slits 31, 32 are provided so as to extend over substantially the whole area of the molded part 4 in a longitudinal direction of the weather strip 1 in substantially a straight line with each other. However, an integral bride portion 33 having no slit exists between the first slit 31 and the second slit 32.

The first slit 31 is formed in the vertical portion and is provided with a first main slit portion 31a and first sub-slit portions 31b, 31c which are formed at ends thereof. The second slit 32 is formed so as to extend over substantially the whole area of the upper side portion into part of the vertical portion by straddling an inner corner portion and is provided with a second main slit portion 32a and sub-slit portions 32b, 32c which are formed at ends thereof. To be more specific, the second main slit portion 32a and one of the second sub-slit portions 32b are formed in the upper side portion, and the other second sub-slit portion 32c is formed in the vertical portion. Note that end edge sides of the first and second sub-slit portions 31b, 31c, 32b, 32c are formed into substantially arc-like shapes, whereby the prevention of generation of cracks is realized.

Next, a molding device 51 will be described which is used to mold the molded part 4 which corresponds to the upper corner part of the weather strip 1.

FIG. 5 is a partially sectional view showing the molding device 51 which is used to mold the molded part 4 as viewed in a lateral direction, and FIGS. 6A, 6B are partially sectional views of the molding device 51 as viewed in a vertical direction. The molding device 51 includes a lower mold 52, which is situated at a lower side as viewed in FIGS. 6A, 6B, an upper mold 53, which is situated at an upper side in the same figures, an outer upper intermediate mold 54 and an outer lower intermediate mold 55, which are situated at an outer side of the upper corner part and an inner upper intermediate mold 56 and an inner lower intermediate mold 57, which are situated at an inner side of the upper corner part. In this embodiment, a sliding mold is made up mainly of the inner lower intermediate mold 57. In addition, a core mold 60 is provided between the inner upper intermediate mold 56 and the inner lower intermediate mold 57.

The core mold 60 is provided with a first core 61 and a second core 62. The first core 61 has a first core main body 63 which forms a vertical portion side of the hollow portion 22 and a first extending plate 64 which extends inwards (downwards as viewed in FIG. 5) from the first core main body 63. The second core 62 has a second core main body 65 which is continuously connected to one end face of the first core main body 63 so as to form an upper side portion side of the hollow portion 22 and a second extending plate 66 which extends inwards (downwards as viewed in FIG. 5) from the second core main body 65.

An intermediate locking projection 71 and a proximal end portion locking projection 72 are integrally formed on the first extending plate 64 so as to extend towards the second extending plate 66. In addition, a proximal end portion locking portion 73 is integrally formed on the second extending plate 66 so as to extend towards the first extending plate 64.

In addition, there are integrally formed on the inner lower intermediate mold 57 which makes up the sliding mold a recessed portion which permits the insertion and passage of the first extending plate 64 and the second extending plate 66 and the sliding movement of the inner lower intermediate mold 57 relative to those plates and a stopper 74 which restricts the movement of the second core 62 and the like. The inner lower intermediate mold 57 is constructed so as to slide to move by a predetermined stroke amount a in vertical directions as viewed in FIG. 5. In this embodiment, the extending direction of the first extending plate 64 and the second extending plate 66 is made to be in parallel with the slide moving direction of the inner lower intermediate mold 57.

Furthermore, first projections 81, 82 for forming the first sub-slits 31b, 31c are integrally formed on a distal end of the inner lower intermediate mold 57. The first projections 81, 82 are made to be brought into surface contact with the first core main body 63 such that they are in close contact with both side edges of the first extending plate 64 when the respective molds 52 to 57, 60 are set in place. In addition, second projections 83, 84 for forming the second sub-slits 32b, 32c are integrally formed on the distal end of the inner lower intermediate mold 57. The second projections 83, 84 are made to be brought into surface contact with the core main bodies such that the one of the second projections 83 is brought into surface contact with the second core main body 65, while the other second projection 84 is brought into surface contact with the first core main body 63 such that the second projections are in close contact with both side edges of the second extending plate 66 when the respective molds 52 to 57, 60 are set in place.

In addition to this, when the respective molds 52 to 57, 60 are set in place, the proximal end portion locking projection 73 on the second extending plate 66 of the second core 62 is locked relative to the stopper 74 on the inner lower intermediate mold 57, and the intermediate locking projection 71 on the first extending plate 64 of the first core 61 is locked relative to the proximal end portion locking projection 73, whereby the positioned states of the respective constituent members are made to be maintained.

Molding surfaces are formed on the respective molds 52 to 57, 60 which constitute a configuration corresponding to the external shape of the molded part 4. In addition, the first core main body 63 of the first core 61 and the second core main body 65 of the second core 62 are set substantially at the center of a space surrounded by the respective molds 52 to 57. Then, a cavity 90 for molding the molded part 4 is formed by these molding surfaces and outer surfaces of the first core main body 63 and the second core main body 65 (refer to FIGS. 6A and 6B) Next, a method for manufacturing the weather strip 1 that is configured as has been described above and the function and advantage associated with the manufacturing thereof will be described. First of all, the extruded parts 2, 3 are molded as has been described above by way of a known extrusion process using an extruding machine, not shown. As a result of the extrusion, the base portion 11, the seal portion 13, the hollow portion 12 and the lip portion 14 are formed.

Next, the molded part 4 will be formed in a manner that will be described below. Namely, as shown in FIG. 7, end portions of the extruded parts 2 and 3 are first fitted on longitudinal end portions of the second core main body 65 and the first core main body 63, respectively, such that the respective molds 52 to 57 are opened relative to each other, whereby the extruded parts 2, 3 are set in place in the molds. In addition, the first core 61 and the second core 62 are set at predetermined positions and the molds are then closed, whereby the extruded parts 2, 3 are mounted and fixed relative to the molding device 51 and the cavity 90 is defined.

Then, from this state, an EPDM rubber or the like, which is in a plasticized state, is, as shown in FIG. 8, injected into the cavity 90 from a gate, not shown, so as to fill the cavity 90 with the rubber. Thereafter, the EPDM rubber is vulcanized and set, and after the completion of setting, the molds are opened sequentially. Namely, the lower mold S2 and the upper mold 53, and the outer upper intermediate mold 54 and the outer lower intermediate mold 55 are first separated from a molded weather strip 1.

Next, as shown by an arrow denoted by [1] in the same figure, the inner lower intermediate mold 57 is caused to slide to move in a direction (downward as viewed in the figure) in which it is separated from the weather strip 1 together with the inner upper intermediate mold 56. Then, the weather strip and the inner upper intermediate mold 56 and the inner lower intermediate mold 57 are separated apart relatively to each other, and the first and second projections 81 to 84 are allowed to be removed, whereby the first sub-slits 31b, 31c, and second sub-slits 32b, 32c which correspond to the projections, respectively, opened. Namely, gaps are formed by these sub-slits (refer to FIG. 9).

Furthermore, removal work of the molded part 4 so molded from the core mold 60 is performed by an worker. Namely, the molded part 4 is first caused to slide to move by an amount equal to the gap relative to the core mold 60 in a direction shown by an arrow indicated by [2] in FIG. 9. Namely, for example, a portion in the vicinity of a joint between the left-hand side extruded part 2, as viewed in the figure, and the molded part 4 is moved in a direction in which it is separated from the second core main body 65, that is, downwardly leftward along a longitudinal direction of the second core main body 65. Then, a distance between a distal end of the second core main body 65 and the second sub-slit 32b is narrowed specifically, and by pulling the portion in the vicinity of the joint between the extruded part 2 and the molded part 4 as shown by an arrow indicated by [3] in the same figure, the molded part 4 can easily be removed from the distal end of the second core main body 65 (the second core main body 65 is removed from the second slits 32). Then, at this point in time, the second core 62 is allowed to be put such that it can be separated from the molded part 4 without any interruption.

Next, from this state, the second core 62 is moved in a direction in which it is separated from the molded part 4 in a direction as shown by an arrow indicated by [4] in the same figure. Then, as shown in FIG. 10, this leaves only the remaining first core 61 situated within the molded part 4. In this state, the molded part 4 is caused to slide to move by the amount equal to the gap in a direction shown by an arrow indicated by [5] in the same figure relative to the first core 61. Namely, a portion in the vicinity of a joint between the right-hand side extruded part 3, as viewed in the figure, and the molded part 4 is moved in a direction in which it is separated from the first core main body 63, that is, downwardly rightward along a longitudinal direction of the first core main body 63. Then, a distance between a distal end of the first core main body 63 and the first sub-slit 31c is narrowed specifically, and by pulling the portion in the vicinity of the joint between the extruded part 3 and the molded part 4 in a direction shown by an arrow indicated by [6] in the same figure, the molded part 4 can easily be removed from the distal end of the first core main body 63. Then, at this point in time, the first core 61 is allowed to be put such that it can be separated from the molded part 4. Consequently, when the molded part 4 is moved to be separated in a direction shown by an arrow indicated by [7] in the same figure along the first core main body 63, the molded part 4 can easily be moved.

Thus, as has been described in detail heretofore, according to the embodiment, the integral bridge portion 33 is formed between the first slit 31 and the second slit 32 which extend longitudinally for ease of the removal of the molds. By this configuration, being different from the related art in which a slit portion needs to be bonded to be closed after molding, no bonding is required by virtue of the integral bridge portion 33. In addition, in designing, no allowance needs to be made for an extent of deformation that would otherwise be caused in association with closure of the slit portion. Consequently, it is possible to realize the suppression of increases in designing and working manhours and costs. Furthermore, since the slit 30 are formed in the base portion 21 for ease of the removal of the molds, being different from a case where slits are formed in the seal portion, it is possible to prevent the occurrence of a risk that the rigidity of the seal portion is damaged by the slits to thereby reduce the sealing properties.

In addition, in this embodiment, the core mold 60, which is used to mold the molded part 4, is provided with the first core 61 and the second core 62, and the first projections 81, 82 and the second projections 83, 84 are provided on the inner lower intermediate mold 57. Then, when removing the core mold 60, first of all, the inner lower intermediate mold 57 is caused to slide to move along the extending direction of the first extending plate 64 and the second extending plate 66, whereby the first projections 81, 82 are separated apart relative to the first core main body 63 and the second projections 83, 84 are separated apart relative to the second core main body 65. Then, the first projections 8.1, 82 and the second projections 83, 84 are removed, whereby openings which constitute part of the slit 30 (that is, the first sub-slits 31b, 31c and the second sub-slits 32b, 32c ) are formed in the sides of the first extending plate 64 and the sides of the second extending plate 66. By this configuration, the molded part 4 is allowed to be moved relative to the first core main body 63 and the second core main body 65. In this embodiment, for example, the second core main body 65 (the second core 62), which is one of the core main bodies, can first be removed from the second slit 32. Then, the first core main body 63 (the first core 61), which is the remaining core main body, can be removed from the first slit 31, which is the other slit, whereby the core mold 60 can easily be removed. In other words, a remarkable improvement in workability during manufacturing can be realized without calling for a complex construction and placing a load on the individual molds that constitute the molding device 51.

In addition, since the slits are limited to two (since the slits provided are not more than three), only the two extending plates 64, 66 are required to form both the slits 31, 32, and no wide space needs to be provided between both the plates 64, 66. Here, when molding the molded part 4 which corresponds to the corner part, in the event that the inner angle of the corner part is relatively small (for example, less than 100 degrees), there is imposed a limitation that the width of the extending plates 64, 66 has to be narrowed. Even in the event that such is the case, the width of the extending plates 64, 66 can be limited to a minimum width without expanding the space between the two extending plates 64, 66. As a result, there is provided an advantage that the damage to the extending plates 64, 66, as well as the core mold 60 and the like can be suppressed, thereby making it possible to extend the life thereof.

Furthermore, in the embodiment, the second slit 32 is formed so as to extend through the inner corner portion of the molded part 4 (in an L-shape fashion). Consequently, by removing first the second core 62 of the core mold 60, the second slit 32 opens in the intersecting direction (in an L-shape). By this configuration, removing work of the remaining first core 61 can be implemented easily. In this respect, a remarkable improvement in workability during manufacturing can be realized.

In association with this, the second slit 32 is formed so as to extend through the inner corner portion by the second projection 84 of the second projections 83, 84 which is brought into contact with the first core main body 63. Namely, not only the extending length of the sub-slit 32b of the second slit 32 but also the widths of the first extending plate 64 and the second extending plate 66 can easily be set by setting the extent of the length of the second projection 84 which is in contact with the first core main body 63. As a result, the design of molds can be made easier.

In addition to this, since the sliding direction of the inner lower intermediate mold 57, the extending direction of the first extending plate 64 and the extending direction of the second extending plate 66 are made to become parallel with each other, they interfere with each other in no case, whereby work involving slide motion and removal can be performed smoothly, and moreover, the molding device 51 can be restrained from getting complex in construction.

On top of that, sine the bridge portion 33 is situated substantially at the center of the molding range of the molded part, even in the event that the bride portion 33 is provided only at a single location as in the case with the embodiment, stress can preferably be absorbed, and the function of the bridge portion can be exhibited to a maximum extent.

Anther aspects of the invention are described below.

(1) A weather strip including a molded part having a base portion and a seal portion which protrudes from the base portion so as to define a hollow portion in the seal portion, wherein

two slits are formed in the base portion of the molded part so as to extend along a longitudinal direction for removal of a core mold and a bridge portion is formed integrally with the base portion between the slits.

(2) The molded part may be formed into substantially an L-shape so as to provide a lateral portion and a vertical portion, and the second slit may be formed so as to extend substantially through the whole area of the lateral portion and partially into the vertical portion, whereas the first slit may be formed in the vertical portion.

According to (2), the lengths of the respective slits can be restrained from scattering, thereby making it possible to equalize stress. In other words, the position where the bridge portion is placed is made difficult to deviate, thereby making it possible to allow the function of the integrally formed bridge portion to be exhibited sufficiently.

(3) An inner angle of the molded part which corresponds to the corner part may be less than 100 degrees.

As has been described above, when the inner angle of the molded part which corresponds to the corner part is relatively small, in particular, when the inner angle is less than 100 degrees, there is imposed the limitation that the widths of the extending plates have to be narrowed. To cope with this, since the two slits are formed, only the two extending plate are necessary, and the space between both the plates does not have to be expanded, a stable molding can be ensured without placing a load on the molding device.

(4) A manufacturing method of a weather strip having a molded part comprising a base portion and a seal portion which protrudes from the base portion so as to define a hollow portion, comprising the steps of:

forming a cavity by a molding device provided with at least a core mold for forming the hollow portion and a sliding mold that is slidable relative to the core mold;

injecting an elastic material which is in a plasticized state into the cavity so as to fill the cavity with the elastic material and then setting the elastic material,

forming a first slit and a second slit in the base portion so as to extend in a longitudinal direction thereof for removal of the core mold in association with the setting of the elastic material, and forming a bridge portion integrally with the base portion between the first and second slits; and

opening the molding device so as to remove the core mold from the first slit and the second slit to thereby obtain the molded part in which the hollow portion is molded; wherein

the core mold includes:

a first core having a first core main body and a first extending plate which extends from the first core main body; and

a second core continuously connected to an end of the first core main body which constitutes a longitudinal end of the weather strip and having a second core main body and a second extending plate which extends from the second core main body; and

the sliding mold comprises:

a pair of first projections which is to be contacted with the first core mainbody at opposite sides of the first extending plate; and

a pair of second projections which is to be contacted with the second main body or the first core main body and the second core main body at opposite sides of the second extending plate;

wherein

the first slit is formed by the first extending plate and the first projection for removal of the first core main body; and

the second slit is formed by the second projection and the second extending plate for removal of the second core main body;

whereby when removing the core mold, the sliding mold is caused to slide to move in a direction in which the first extending plate and the second extending plate extend such that the first projection is separated relatively from the first core main body and the second projection is separated relatively from the second core main body or the first core main body and the second core main body, so that the first core main body and the second core main body are removed from the first slit and the second slit, respectively.

According to (4), the core mold that is used for molding the hollow portion includes the first core and the second core, and the sliding mold includes at least the pair of first projections which is to be contacted with the first core main body at both the sides of the first extending plate and the pair of second projections which is to be contacted with the second main body or the first core main body and the second core main body at both the sides of the second extending plate. Then, when removing the core mold, the first projection is separated relatively from the first core main body and the second projection is separated from the second core main body or the first core main body and the second core main body by sliding the sliding mold along the extending direction of the first extending plate and the second extending plate. Then, the first projection and the second projection are removed, whereby openings, which constitute part of the slits, are formed in both the sides of the first extending plate and both the sides of the second extending plate. By this configuration, a molded body can be moved relatively to the first core main body and the second core main body with a wider degree of freedom, whereby one of the core main bodies can be removed from one of the slits by virtue of the relative movement. Then, when the remaining core main body is removed from the other slit, the core mold can easily be removed. In other words, a further improvement in workability during manufacturing can be realized.

(5) The molded part may be formed into substantially an L-shape so as to correspond to a corner part, and the second slit may be formed so as to extend through an inner corner portion.

According to (5), the second slit is formed so as to extend through the inner corner portion of the molded part. Consequently, when the second core of the core mold is first removed, the second slit opens in the intersecting direction (in an L-shape). By this configuration, removing work of the remaining first core can be implemented easily. In this respect, a remarkable improvement in workability during manufacturing can be realized.

(6) When the elastic material is injected, the second projection may be made to contact with at least the first core main body such that the second projection is in close contact with a side portion of the second extending plate.

According to (6), the second slit is formed so as to extend through the inner corner portion by the side of the second projection which is brought into contact with the first core main body. Namely, not only the extending length of the second slit but also the widths of the first extending plate and the second extending plate can easily be set by setting the extent of the length of the second projection which is in contact with the first core main body. As a result, the design of molds can be made easier.

(7) A sliding direction of the sliding mold, an extending direction of the first extending plate and an extending direction of the second extending plate may be made to be in parallel with each other.

According to (7), since the sliding direction of the sliding mold, the extending direction of the first extending plate and the extending direction of the second extending plate become parallel with each other, they interfere with each other in no case, whereby work such as sliding removal or the like can be performed, and moreover, the molding device can be restrained from getting complex in construction.

(8) The molded part may be formed such that both ends of an extruded part which is formed separately are connected to each other or respective ends of a plurality of extruded parts are connected to each other.

According to (8), even when the molded part is formed such that an end portion of an extruded part which is formed separately is connected thereto, the core mold can easily be removed.

(9) A molding device of a weather strip, comprising:

a core mold and a sliding mold which is provided slidably relative to the core mold for forming a molded part of a weather strip which comprises a base portion and a seal portion which protrudes from the base portion so as to form a hollow portion,

wherein

the core mold includes:

a first core having a first core main body and a first extending plate which extends from the first core main body for forming the hollow portion; and

the sliding mold includes:

a pair of first projections which is to be contacted with the first core main body such that the first projections are brought in a close contact with opposite sides of the first extending plate; and

a pair of second projections which are to be contacted with the second main body or the first core main body and the second core main body at least such that the second projections are brought in close contact with opposite sides of the second extending plate.

According to (9), basically, the same function and advantage as those provided by (4) are provided.

(10) The molded part may be formed into substantially an L-shape so as to correspond to a corner part, and the second projection may be provided so as to extend through an inner corner portion of a portion which corresponds to the corner part so as to be brought into contact with at least the first core main body such that the second projection is in close contact with a side portion of the second extending plate.

According to (10), the second projection is provided so as to extend through the inner corner portion which is a portion corresponding to the corner part so as to be brought into contact with the first core main body and the second core main body such that the second projection is in close contact with a side portion of the second extending portion. By this configuration, one (the second slit) of the two slits to be formed is formed so as to extend through the inner corner portion. Consequently, by removing first the second core of the core mold, the slit corresponding thereto opens in the intersecting direction (in an L-shape). By this configuration, removing work of the remaining first core can easily be performed. In this respect, a remarkable improvement in workability during manufacturing can be realized.

Note that the invention is not limited to what has been described heretofore with respect to the embodiment but may be embodied, for example, in ways that will be described below. Applications and alterations that will not be described below are, of course, acceptable.

(a) While, in the embodiment, the first slit 31 and the second slit 32 are provided substantially in a straight line, they are not necessarily provided on the same line but may be formed such that they deviate from each other in a widthwise direction.

(b) While, in the embodiment, nothing particular is mentioned, the slits which intersect in the longitudinal direction of the slit 30 (for example, the slits which intersect in a perpendicular direction) may be formed so as to extend further. By adopting this configuration, the removal work of the core mold 60 can be performed more smoothly.

(c) While, in the embodiment, the inner corner portion is specifically described as being at less than 100 degrees, there will be no problem even in case the inner corner portion is formed at an angle which exceeds 100 degrees. For example, the invention can be applied to a weather strip having a molded part which has an inner angle of 100 degrees or greater but has a very small area.

(d) While, in the embodiment, the case is specified in which the second core 62 is first removed and thereafter, the first core 61 is removed, the first core 61 maybe removed first.

(e) As has been described above, the weather strip has flexibility. By this configuration, the lengths of the respective sub-slits 31b, 31c, 32b, 32c may be altered appropriately, provided that the first core main body 63 and the second core main body 65 can be removed from the weather strip 1 (the molded part 4). Furthermore, while, in the embodiment, the respective sub-slits 31b, 31c, 32b, 32c are provided at both the sides of the extending plates 64, 66, that is, the pairs of projections 81 to 84 are provided which correspond to those sub-slits, respectively, the sub-slits or the projections are not necessarily provided at the four locations, and for example, they may be provided only at two locations (that is, only projections 81, 84) on the center side (the corner portion side). In addition, only three projections including the aforesaid two projections (that is, the projections 81, 84 and the projection 83 corresponding to the second core 62 which is removed first) may be provided.

(f) While, in the embodiment, the projections 81 to 84 are described as being provided on the inner lower intermediate mold 57, they may be provided on the inner upper intermediate mold 56.

(g) While, in the embodiment, the inner upper intermediate mold 56 and the inner lower intermediate mold 57 are described as being caused to slide to move, the core mold 60 may be made to slide to move together with the weather strip 1.

(j) While, in the embodiment, nothing particular is mentioned, a clip attaching hole may be provided in the molded part 4, or an insert may be provided (embedded) in the molded part 4.

Weather strip, manufacturing method thereof and molding device

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