Donnelly Corporation

Sabina J Houle

Daniel J Fisher

Douglas Crank

James L Brodie

Marc A Lovell

A single-sided gasketed panel assembly for use as a flush-mounted panel or window in vehicles, buildings, or other structures, as well as a method and apparatus for making such panel assemblies, wherein the panel assembly comprises a sheet-like panel having; a primer layer and at least one polymeric gasket molded to the panel on the primer layer. The primer applied to the panel has a predetermined transition temperature above which improved adhesion properties are exhibited for polymeric gaskets molded thereon when the primer is at or above such temperature. In a preferred embodiment, a gasket is molded from a thermoplastic polymeric material such as PVC onto the primed portion of the panel while the panel is at or above the transition temperature. The resulting bond between the gasket and panel can withstand a shear force greater than 300 pounds per square inch at a rate of 25 millimeters per minute and a 180.degree. peel test force greater than 30 pounds per linear inch at a rate of 25 millimeters per minute after soaking for at least 250 hours in water having a temperature greater than 175.degree. F. The method for manufacturing the panel assembly includes applying a primer having a predetermined transition temperature as a coating to a surface of a panel, heating the panel and primer coating to a temperature at least equal to the transition temperature of the primer, and molding a gasket, preferably of a thermoplastic polymeric material, onto the surface of the heated panel and the primer coating while the temperature of the primer coating is at least equal to the primer transition temperature. The preferred mold assembly includes a mold cavity defined in a facing surface of one mold section and a heat insulative pad in the second mold section, the pad being urged against the surface of a sheet-like panel at a position opposite the mold cavity when the mold sections are closed.

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Holland, MI, United States of America

Sabina J Houle