Systems and methods for manufacturing reinforced weatherstrip

A method of making a weatherstrip comprising a foam profile, a resin coating, and a cover layer, the method comprising the steps of:

• providing a foam profile;
• providing a cover layer, wherein the cover layer comprises a strip with edges;
• guiding the cover layer into at least one of a desired position, orientation, and contour relative to the foam profile using an applicator die comprising at least one of a plate forming a shaped opening and a guide;
• and
• passing the cover layer and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of the foam profile are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.

A method of making a weatherstrip comprising a foam profile, a resin coating, and a cover layer, the method comprising the steps of:

• providing a foam profile;
• dispensing a cover layer from a roll, wherein the cover layer comprises a strip with edges;
• guiding the cover layer into at least one of a desired position, orientation, and contour relative to the foam profile using an applicator die comprising at least one of a plate forming a shaped opening and a guide;
• and
• passing the cover layer and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of the foam profile are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.

A system for manufacturing weatherstrip, the system comprising:

• a foam profile source;
• a stiffener source;
• a cover layer source, wherein the cover layer comprises a strip with edges;
• a resin source;
• a device for attaching the stiffener to the foam profile;
• an applicator die comprising at least one of a plate forming a shaped opening and a guide, wherein the applicator die is for guiding the cover layer into at least one of a desired position, orientation, and contour relative to at least one of the foam profile and the stiffener;
• and
• a coating die for receiving the foam profile, the stiffener, and the cover layer and for coating the edges of the cover layer and at least one of the foam profile and the stiffener with resin to anchor the cover layer.

A method of making a weatherstrip comprising a cover layer and at least one of a foam profile and a stiffener, the method comprising the steps of:

• providing the cover layer, wherein the cover layer comprises a strip with edges;
• providing at least one of the foam profile and the stiffener;
• applying at least a portion of the cover layer to the at least one of the foam profile and the stiffener to create a combined component, wherein the cover layer is applied using at least one of (i) an applicator die comprising at least one of a plate forming a shaped opening and a guide, and (ii) a plurality of wheels;
• and
• passing the combined component through an ultrasonic welding station, thereby securing the edges of the cover layer to the at least one of the foam profile and the stiffener.

A method of making a weatherstrip comprising a foam profile, a resin coating, and a cover layer, the method comprising the steps of:

• providing a foam profile;
• guiding a cover layer into at least one of a desired position, orientation, and contour relative to at least a portion of the foam profile using an applicator die comprising at least one of a plate forming a shaped opening and a guide, wherein the cover layer is from a roll and comprises a strip with edges;
• and
• passing the cover layer and the foam profile through a resin coating die, wherein the edges of the strip and discrete portions of the foam profile are coated with resin to anchor the cover layer, while the resin is in a substantially liquid state.