Extruded sealed fastener

Patent metadata

Field	Value
Publication number	US-11931945-B2
Application number	US-202017074856-A
Country	US
Kind code	B2
Filing date	Oct 20, 2020
Priority date	Oct 20, 2020
Publication date	Mar 19, 2024
Grant date	Mar 19, 2024

Abstract

A method of forming a plurality of fasteners includes extruding a continuous strip of material, the continuous strip defining a base portion, a tip portion, and a stem portion extending between the base portion and the tip portion. A portion of material is removed from the continuous strip of material along the tip portion such that a plurality of tip portions are separated from each other and spaced apart, each tip portion having at least one flexible tab. The continuous strip of material is then extruded through a foaming die, wherein the flexible tabs are elastically displaced away from the base portion during a foaming process such that a foam material fills a cavity of the foaming die to form a sealing element around the stem portion. Portions of the continuous strip between each of the tip portions are separated to produce a plurality of individual sealed fasteners.

First claim

What is claimed is:

1. A method of forming a plurality of fasteners, the method comprising:
extruding a continuous strip of material, the continuous strip of material defining a base portion, a tip portion, and a stem portion extending between the base portion and the tip portion;
removing a portion of material from the continuous strip of material along the tip portion such that a plurality of tip portions are separated from each other and spaced apart, each tip portion having at least one flexible tab; and
extruding the continuous strip of material through a foaming die, wherein the flexible tabs are elastically displaced away from the base portion during a foaming process such that a foam material fills a cavity within the foaming die and forms a sealing element around the stem portion.

2. The method according to claim 1 , further comprising cooling the continuous strip of material before removing the portion of material along the tip portion.

3. The method according to claim 2 , further comprising drying the continuous strip of material after the cooling.

4. The method according to claim 1 , wherein the flexible tabs are displaced away from the base portion sequentially along a longitudinal direction of the continuous strip of material.

5. The method according to claim 4 , wherein the flexible tabs are displaced by a ramp feature of the foaming die.

6. The method according to claim 1 , wherein excess foam is removed from the continuous strip of material after the foaming process.

7. The method according to claim 1 , wherein the continuous strip of material is thermoplastic.

8. The method according to claim 1 , wherein the foam material is a thermoplastic elastomer (TPE) or a polyurethane.

9. The method according to claim 1 , wherein a metered volume of the foam material and a foaming agent are injected through gates on opposite sides of the continuous strip of material around the stem portion.

10. A method of forming a plurality of fasteners, the method comprising:
extruding a continuous strip of material, the continuous strip defining a base portion, a tip portion, and a stem portion extending between the base portion and the tip portion;
removing a portion of material from the continuous strip of material along the tip portion such that a plurality of tip portions are separated from each other and spaced apart, each tip portion having at least one flexible tab;
extruding the continuous strip of material through a foaming die, wherein the flexible tabs are elastically displaced away from the base portion during a foaming process such that a foam material fills a cavity of the foaming die and forms a sealing element around the stem portion; and
separating portions of the continuous strip between each of the tip portions to produce a plurality of individual sealed fasteners.

11. The method according to claim 10 , wherein the flexible tabs are displaced away from the base portion sequentially along a longitudinal direction of the continuous strip of material.

12. The method according to claim 11 , wherein the flexible tabs are displaced by a ramp feature of the foaming die.

13. The method according to claim 10 , wherein a metered volume of the foam material and a foaming agent are injected through gates on opposite sides of the continuous strip of material around the stem portion.

Assignees

• Ford Global Tech Llc

Inventors

• Dellock Paul Kenneth
• Salter Stuart C
• Glickman David Brian

Classifications

• B29C48/12 Primary

  Articles with an irregular circumference when viewed in cross-section, e.g. window profiles · CPC title

• B29C44/332

  the preformed parts being three-dimensional structures · CPC title

• B29C48/0012

  combined with shaping by internal pressure generated in the material, e.g. foaming · CPC title

• B29C48/0022

  combined with cutting · CPC title

• B29C48/155

  Partial coating thereof · CPC title