Polymeric roof rail

Abstract

A convertible roof system uses composite roof rail(s). The composite roof rail can have portions that are made of differing materials. The composite roof rail can use universal connecting pieces for the ends of the roof rail. Adjacent composite roof rails can be formed about a connector that couples the adjacent roof rails together.

1 . A convertible roof system for an automotive vehicle, the system comprising: 
 a top stack mechanism operable between extended and retracted positions, said top stack mechanism including: 
 a first roof rail;  
 a second roof rail;  
 a connector pivotally coupling said first and second roof rails together; and  
 wherein at least one of said first and second roof rails are formed around said connector.  
   
   
   
       2 . The system of  claim 1 , wherein said first and second roof rails are made from polymeric material.  
   
   
       3 . The system of  claim 2 , wherein said first and second rails are injection molded around said connector.  
   
   
       4 . The system of  claim 1 , wherein said first and second roof rails are made from metal.  
   
   
       5 . The system of  claim 1 , wherein said connector is made from polymeric material.  
   
   
       6 . The system of  claim 1 , wherein said connector is made from metal.  
   
   
       7 . The system of  claim 1 , wherein a portion of said connector is knurled.  
   
   
       8 . The system of  claim 1 , further comprising a pliable cover and wherein said top stack mechanism supports a portion of said cover.  
   
   
       9 . A convertible roof member comprising: 
 a carbon substrate; and    a metallic coating on said carbon substrate.    
   
   
       10 . The convertible roof member of  claim 9 , wherein said carbon substrate is a carbon fiber-reinforced substrate.  
   
   
       11 . The convertible roof member of  claim 9 , wherein said metallic coating is a spray deposited metallic coating.  
   
   
       12 . The convertible roof member of  claim 9 , wherein said metallic coating is steel.  
   
   
       13 . A method of making a convertible roof system for an automotive vehicle wherein the convertible roof system includes a top stack mechanism operable between extended and retracted position and wherein the top stack mechanism includes at least first and second roof rails pivotally coupled together with a connecting hinge assembly, the method comprising: 
 (a) positioning the connecting hinge assembly in a mold;    (b) forming the first roof rail around a portion of the connecting hinge assembly so that said portion of the connecting hinge assembly is encapsulated within the first roof rail; and    (c) forming the second roof rail around a different portion of the connecting hinge assembly so that said different portion of the connector is encapsulated within the second roof rail.    
   
   
       14 . The method of  claim 13 , further comprising forming the first and second roof rails in said mold.  
   
   
       15 . The method of  claim 13 , further comprising injection molding at least one of the first and second roof rails in said mold.  
   
   
       16 . The method of  claim 13 , further comprising casting at least one of the first and second roof rails in said mold.  
   
   
       17 . The method of  claim 13 , wherein said first and second roof rails are molded concurrently.  
   
   
       18 . The method of  claim 13 , wherein said first and second roof rails are molded consecutively.  
   
   
       19 . The method of  claim 13 , further comprising applying a mold release agent to at least one section of the connecting hinge assembly to prevent the roof rail encapsulating said section of the connecting hinge assembly from adhering to said section of the connecting hinge assembly.  
   
   
       20 . The method of  claim 13 , wherein (b) and (c) include forming an integral seal retainer in the first and second roof rails.  
   
   
       21 . The method of  claim 13 , wherein (b) and (c) include forming the first and second roof rails with polymeric material.  
   
   
       22 . The method of  claim 13 , wherein (b) and (c) include forming the first and second roof rails with metal.