Method for making multiple durometer bulb seals

A method for making multiple durometer bulb seals, comprising

• providing a first material;
• providing a second material having a lower durometer than said first material;
• providing at least one first main extruder;
• providing at least one first calibrator device located in-line and downstream from said first main extruder, said at least one first calibrator device is a vacuum calibrator;
• providing at least one first cooling tank located in-line and downstream from said first calibrator device;
• providing at least one first pulling device located in-line and downstream from said first cooling tank for pulling an extrusion along a longitudinal axis;
• providing at least one downstream extruder located in-line and downstream from said first pulling device;
• providing at least one second calibrator device located in-line and downstream from said downstream extruder;
• providing at least one second cooling tank located in-line and downstream from said second calibrator;
• providing at least one second pulling device located in-line and downstream from said second cooling tank for pulling said extrusion along said longitudinal axis;
• providing at least one cutting device located in-line and downstream from said second pulling device;
• heating a first material to about 315 to 420° C. in said at least one first main extruder;
• extruding said first material for forming a structural member;
• pulling said structural member using said first pulling device through said first calibrator device, said first calibrator device forming a final profile of said structural member;
• cooling said structural member in a cooling medium located in said first cooling tank to about 80 to 100° C., said cooling medium contacting outer and inner surfaces of said structural member;
• extruding said second material with said at least one downstream extruder to form a bulb portion;
• bonding said bulb portion to said structural member;
• pulling said structural member and bulb portion using said second pulling device through said second calibrator device, said second calibrator device forming a final profile of said bulb portion;
• pulling said structural member and bulb portion using said second pulling device through said second cooling tank;
• cooling said bulb portion in a cooling medium located in said second cooling tank to about 80 to 100° C.;
• and
• cutting said structural member and bulb portion to provide bulb seals having a predetermined length.

A method for making multiple durometer bulb seals, comprising

• providing a first material for forming a structural member having a first durometer of about 40-70 Shore D;
• providing a second material for forming a bulb portion having a durometer of about 35-85 Shore A;
• providing at least one first main extruder;
• providing at least one first calibrator device located in-line and downstream from said first main extruder, said at least one first calibrator device is a vacuum calibrator;
• providing at least one first cooling tank located in-line and downstream from said first calibrator device;
• providing at least one first pulling device located in-line and downstream from said first cooling tank for pulling an extrusion along a longitudinal axis;
• providing at least one downstream extruder located in-line and downstream from said first pulling device;
• providing at least one second calibrator device located in-line and downstream from said downstream extruder;
• providing at least one second cooling tank located in-line and downstream from said second calibrator;
• providing at least one second pulling device located in-line and downstream from said second cooling tank for pulling said extrusion along said longitudinal axis;
• providing at least one cutting device located in-line and downstream from said second pulling device;
• heating a first material to about 315 to 420° C. in said at least one first main extruder;
• co-extruding said first material for forming said structural member;
• pulling said structural member using said first pulling device through said first calibrator device, said first calibrator device forming a final profile of said structural member;
• cooling said structural member in a cooling medium located in said first cooling tank to about 80 to 100° C., said cooling medium contacting outer and inner surfaces of said structural member;
• extruding said second material with said at least one downstream extruder to form said bulb portion;
• melt bonding said bulb portion to said structural member;
• pulling said structural member and bulb portion using said second pulling device through said second calibrator device, said second calibrator device forming a final profile of said bulb portion;
• pulling said structural member and bulb portion using said second pulling device through said second cooling tank;
• cooling said bulb portion in a cooling medium located in said second cooling tank to about 80 to 100° C.;
• and
• cutting said structural member and bulb portion to provide bulb seals having a predetermined length;
• wherein said structural member and bulb portion are not co-extruded;
• wherein said at least one first main extruder, at least one first calibrator device, at least one first cooling tank, at least one first pulling device, at least one downstream extruder, at least one second calibrator device, at least one second cooling tank, at least one second pulling device, and at least one cutting device have an in-line arrangement of features along a longitudinal axis;
• and
• wherein said in-line arrangement of features and separate cooling of said structural member and said bulb portion in said method for making multiple durometer bulb seals avoids or overcomes or diminishes a predetermined disparity in cooling expansion and cooling differentials between said different durometers.