One-piece vehicle roof rail

Abstract

A roof rail for a vehicle is provided that is made of only one piece and is solid across its length. The roof rail may be made using a co-injection molding process, a two-shot injection molding process or an extrusion molding process.

What is claimed is: 
     
         1 . A roof rail for a vehicle including:
 an elongated main body portion extending between a pair of ends;   a pair of connecting portions each located at one of the ends of the main body portion; and   the main body portion and the connecting portions being integrally connected to one another and of an injection molded thermoplastic such that the roof rail is comprised of only one piece.   
     
     
         2 . A roof rail as set forth in  claim 1  wherein the roof rail has an inner portion of a first thermoplastic material surrounded by an outer portion of a second thermoplastic material. 
     
     
         3 . A roof rail as set forth in  claim 2  wherein the inner and outer portions of the roof rail are formed with a co-injection molding process. 
     
     
         4 . A roof rail as set forth in  claim 2  wherein the inner and outer portions of the roof rail are formed with a two-shot injection molding process. 
     
     
         5 . A roof rail as set forth in  claim 4  wherein a metal plating layer is positioned about the outer portion of the roof rail. 
     
     
         6 . A roof rail as set forth in  claim 2  wherein a paint surrounds the outer portion. 
     
     
         7 . A roof rail as set forth in  claim 1  wherein the elongated main body has an upper surface and a lower surface opposite the upper surface for overlying a roof of the vehicle, and wherein the lower surface defines a plurality of tie down slots for allowing users to tie items to the rails. 
     
     
         8 . A roof rail as set forth in  claim 1  wherein a plurality of rope hooks are each connected to one of the ends of the main body portion. 
     
     
         9 . A roof rail as set forth in  claim 1  wherein the elongated main body includes an elongated back wall and an elongated front wall positioned in spaced relationship with one another, and wherein the elongated main body includes an elongated top wall extending between the back wall and the front wall to define a compartment between the back wall, front wall and the top wall. 
     
     
         10 . A roof rail as set forth in  claim 5  wherein the top wall extends from the back wall to a terminal end that is past the front wall, and wherein the front wall extends from the top wall at angle relative to the back wall. 
     
     
         11 . A roof rail as set forth in  claim 5  wherein a bottom wall extends between the back wall and the front wall in spaced and generally parallel relationship with the top wall to close the compartment. 
     
     
         12 . A roof rail as set forth in  claim 7  wherein a seal is positioned against the bottom wall for in order to minimize rattling of the roof rail. 
     
     
         13 . A method of forming a roof rail for a vehicle including:
 injection molding with at least one thermoplastic material an elongated main body portion extending between a pair of ends, and a pair of connecting portions each at one of the ends of the main body portion, wherein the main body portion and the connecting portions are integral with one another.   
     
     
         14 . A method of forming a roof rail as set forth in  claim 13  wherein injection molding includes a co-injection molding process, and wherein an inner portion of a first thermoplastic material is formed and wherein an outer portion of a second thermoplastic material is formed, with the outer portion surrounding the inner portion. 
     
     
         15 . A method of forming a roof rail as set forth in  claim 13  wherein injection molding includes a two-shot injection molding process, and wherein an inner portion of a first thermoplastic material is formed and wherein an outer portion of a second thermoplastic material is formed, with the outer portion surrounding the inner portion. 
     
     
         16 . A method as set forth in  claim 15  further including electroplating a metal plating layer about the outer portion of the roof rail. 
     
     
         17 . A roof rail as set forth in  claim 16  wherein the inner portion if of a non-conductive material and the outer portion is of a conductive material. 
     
     
         18 . A roof rail for a vehicle including:
 an elongated main body portion extending between a pair of ends;   a pair of connecting portions each attached to one of the ends of the main body portion; and   the main body portion and the connecting portions being integrally connected to one another and of an extruded thermoplastic material such that the roof rail is comprised of only one piece.   
     
     
         19 . A roof rail as set forth in  claim 18  wherein the roof rail has an inner core portion of a first thermoplastic material surrounded by an outer portion of a second thermoplastic material. 
     
     
         20 . A method of forming a roof rail for a vehicle including:
 extruding a thermoplastic material into an elongated main body portion extending between a pair of ends, and a pair of connecting portions each at one of the ends of the main body portion, wherein the main body portion and the connecting portions being integral with one another.   
     
     
         21 . A method as set forth in  claim 20  wherein the main body portion has at least a first portion and a second portion and wherein extruding a thermoplastic material into an elongated main boy portion includes extruding a first thermoplastic material to form the first portion and extruding a second thermoplastic material to form the second portion.