CN116967708A - Co-extrusion roll formed roof ditch molding with end forming features - Google Patents

Co-extrusion roll formed roof ditch molding with end forming features Download PDF

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Publication number
CN116967708A
CN116967708A CN202210420911.4A CN202210420911A CN116967708A CN 116967708 A CN116967708 A CN 116967708A CN 202210420911 A CN202210420911 A CN 202210420911A CN 116967708 A CN116967708 A CN 116967708A
Authority
CN
China
Prior art keywords
strip
roof ditch
molding
flat
ditch molding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202210420911.4A
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Chinese (zh)
Inventor
保罗·肯尼士·戴尔洛克
大卫·布莱恩·格利克曼
斯图尔特·C·索尔特
迈克尔·A·穆斯利赫
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ford Global Technologies LLC
Original Assignee
Ford Global Technologies LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ford Global Technologies LLC filed Critical Ford Global Technologies LLC
Priority to CN202210420911.4A priority Critical patent/CN116967708A/en
Publication of CN116967708A publication Critical patent/CN116967708A/en
Pending legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P2700/00Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
    • B23P2700/50Other automobile vehicle parts, i.e. manufactured in assembly lines

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Abstract

The present disclosure provides "co-extrusion roll formed roof ditch molding with end forming features". Apparatus and methods according to exemplary aspects of the present disclosure include, among other things, cutting opposing notches in side edges of a flat metal strip to provide a flat grooved strip having pairs of notches extending along a length of the flat grooved strip. The flat grooved strip is roll formed to provide a profiled grooved strip and a flexible material is extruded to cover the profiled grooved strip to provide a roof ditch molding. Cutting the roof ditch molding at a slot location to achieve a desired molding length extending between molding cut ends including tabs, and removing a pattern of flexible material from the slot associated with the molding cut ends. The tab is bent to provide a final shaped end for the roof ditch molding.

Description

Co-extrusion roll formed roof ditch molding with end forming features
Technical Field
The present disclosure relates generally to methods and apparatus for providing roof ditch molding that includes end forming features that eliminate the need for end caps.
Background
The vehicle may include a roll formed roof ditch molding that is overmolded with a soft material to seal along the sides of the roof. The molding typically has a separately attached end cap to provide an elegant appearance. Forming and installing the individual end caps is labor intensive and cost prohibitive. Other roof ditch moldings have stamped ends that are formed by employing existing shaping/extrusion roof ditch moldings and cutting off the edges of the ditch molding to shape the ends of the ditch molding. The stamping process is labor intensive and can have a high reject rate.
Disclosure of Invention
The method according to an exemplary aspect of the present disclosure comprises, inter alia: cutting opposing notches in side edges of the flat metal strip to provide a flat slotted strip having pairs of notches extending along a length of the flat slotted strip; roll forming a flat grooved strip to provide a profiled grooved strip; extruding a flexible material to cover the profiled slotted strip to provide a roof ditch molding; cutting the roof ditch molding at a slot location to achieve a desired molding length extending between molding cut ends including tabs, and removing the pattern of flexible material from the slot associated with the molding cut ends; and bending the tab to provide a final shaped end for the roof ditch molding.
In yet another non-limiting embodiment of the foregoing method, the flat metal strip has opposite side edges extending along a length of the flat metal strip and spaced apart from each other by a width of the flat metal strip, and wherein a first notch is cut in one of the opposite side edges and a second notch is cut in the other of the opposite side edges aligned across the width with the first notch to form one pair of the notches, and wherein the other pair of notches are formed spaced apart from each other along the length to form a flat slotted strip.
In yet another non-limiting embodiment of any of the foregoing methods, the pattern of flexible material removed from the slot includes a triangular pattern such that a tapered surface is provided from each side edge of the roof ditch molding toward the distal end of the tab.
In yet another non-limiting embodiment of any of the foregoing methods, the method includes placing the roof ditch molding in a stretch bender, shaping the roof ditch molding to fit the contour of the roof, and bending the tabs at the cut end of each molding to provide a final shaped end.
In yet another non-limiting embodiment of any of the foregoing methods, the flat metal strip is made of an aluminum material and wherein the flexible material comprises plastic.
A method according to yet another exemplary aspect of the present disclosure comprises, inter alia: shaping a flat metal strip; forming a slot in a flat metal strip to provide a flat slotted strip; roll forming a flat grooved strip to provide a profiled grooved strip; extruding a flexible material to cover the profiled grooved strip to provide a co-extruded roll-formed roof ditch molding; cutting the co-extrusion roll formed roof ditch molding to a desired length to provide a roof ditch molding having cut ends at a slot location to provide a tab at each cut end; removing the pattern of flexible material from the slot associated with the cut end; and bending the tab to provide a final shaped end for the roof ditch molding.
In yet another non-limiting embodiment of any of the foregoing methods, the flat metal strip is made of an aluminum material.
In yet another non-limiting embodiment of any of the foregoing methods, the flexible material comprises plastic.
In yet another non-limiting embodiment of any of the foregoing methods, the method includes unwinding a continuous metal strip from a roll and passing the continuous metal strip through a flattening machine to provide a flat metal strip.
In yet another non-limiting embodiment of any of the foregoing methods, the method includes passing the flat metal strip through a take-up ring or restrictor to allow a downstream portion of the flat metal strip to stop long enough to form a notch in the flat metal strip while maintaining a consistent deployment rate of the continuous metal strip.
In yet another non-limiting embodiment of any of the foregoing methods, the method includes feeding a downstream portion of the flat metal strip into a hydraulic punch to form a slot along a length of the flat metal strip such that a flat slotted strip is formed.
In yet another non-limiting embodiment of any of the foregoing methods, the method comprises: forming a profiled grooved strip in a roll former to have a C-shaped section profile; extruding a flexible material to form and cover the entire C-shaped section profile to form a co-extruded roll-formed roof ditch molding; and feeding the co-extruded roll-formed roof ditch molding into a cutter.
In yet another non-limiting embodiment of any of the foregoing methods, the pattern of flexible material removed from the cut end includes a triangular pattern such that a tapered surface is provided from each side edge of the roof ditch molding toward the distal end of the tab.
In yet another non-limiting embodiment of any of the foregoing methods, the method includes placing a roof ditch molding in a stretch bender, molding the molding to fit the contour of the roof, and bending tabs at each end of the roof ditch molding to provide a final molded end.
In yet another non-limiting embodiment of any of the foregoing methods, the flat metal strip has opposite side edges extending along a length of the flat metal strip and spaced apart from each other by a width of the flat metal strip, and wherein a first notch is cut in one of the opposite side edges and a second notch is cut in the other of the opposite side edges aligned across the width with the first notch to form a pair of notches, and wherein the other pair of notches are formed spaced apart from each other along the length to form a flat slotted strip.
In yet another non-limiting embodiment of any of the foregoing methods, the pattern of flexible material removed from the slot includes a triangular pattern such that a tapered surface is provided from each side edge of the roof ditch molding toward the distal end of the tab.
In yet another non-limiting embodiment of any of the foregoing methods, the method includes bending the tab at each cut end to provide a final shaped end.
An apparatus according to yet another exemplary aspect of the present disclosure includes, among other things, a first cutter for cutting opposing notches in side edges of a flat metal strip to provide a flat grooved strip having pairs of notches extending along a length of the flat grooved strip. The roll former receives a flat grooved strip and roll forms the flat grooved strip to provide a profiled grooved strip. An extruder receives the profiled grooved strip and extrudes a flexible material to cover the profiled grooved strip to provide a roof ditch molding. The second cutter cuts the roof ditch molding at the slot location to achieve a desired length extending between the cut ends including the tabs and removes the pattern of flexible material from the slot associated with the cut ends. The stretch bender forms the roof ditch molding to fit the contour of the vehicle roof and bends the tabs to provide a final shaped end for the roof ditch molding.
An apparatus according to yet another exemplary aspect of the present disclosure includes, among other things, a pre-grooved strip shaped to have a profile extending between notches disposed at opposite strip ends, each end including a tab. The flexible material covers the profile such that the entire pre-grooved strip is covered with the flexible material to include a roof ditch molding configured to fit along an edge of the vehicle roof. The flexible material provides a tapered surface extending from each side edge of the roof ditch molding toward the distal end of the tab. Each tab is configured to provide a curved portion that forms a finished end for a roof ditch molding.
In yet another non-limiting embodiment of any of the foregoing apparatus, the profile comprises a C-shaped profile.
Embodiments, examples, and alternatives (including any of their various aspects or respective individual features) of the preceding paragraphs, claims, or the following description and drawings may be employed separately or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.
Drawings
The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The drawings that accompany the detailed description can be briefly described as follows:
FIG. 1 illustrates a perspective view of a vehicle roof having a roof ditch molding assembly with a final shaped end.
FIG. 2 illustrates a schematic view of an apparatus for manufacturing the roof ditch molding assembly of FIG. 1.
FIG. 3 is a top view of a flat metal strip for forming a roof ditch molding assembly.
Fig. 4 is a top view of a flat slotted strap formed from a flat metal strap.
FIG. 5 is a perspective view of a roll forming apparatus that forms a flat grooved strip into a profiled grooved strip.
Fig. 6 is a top view of a profiled grooved strip with a soft flexible material extruded over the entire profiled grooved strip.
FIG. 7 is an enlarged view of a portion of the profiled grooved strip of FIG. 6 showing the cutting pattern of the notch locations.
Fig. 8A shows a roof ditch molding cut to a desired length and having cut ends.
FIG. 8B is an enlarged view of one of the cut ends of FIG. 8A and shows the tab to be bent to form the final formed end of the roof ditch molding assembly.
Detailed Description
The present disclosure details an exemplary roof ditch molding that includes a pre-formed notch prior to roll forming and extrusion to provide a finished end feature of the molding that does not require an end cap.
Referring to FIG. 1, a vehicle 10 has a roof 12 that includes a channel known as a roof ditch 14. Roof ditch 14 is a channel within roof 12 that directs water away from the sides of the vehicle and may also include attachment welds securing the roof to the vehicle. The ditch molding assembly 16 covers the roof ditch 14 and provides a desired aesthetic appearance and water management function.
Fig. 2 shows an apparatus 20 for manufacturing the roof ditch molding assembly 16. A method of manufacturing the roof ditch molding assembly 16 using the apparatus 20 includes first forming a flat metal strip 22, as shown in fig. 3. The apparatus 20 includes a cutting device that then forms a slot 24 in the flat metal strip 22 to provide a flat slotted strip 26, as shown in fig. 4. After forming the grooved strip 26, it is fed into a roll former to provide a profiled grooved strip 28, as shown in FIG. 5. Next, a flexible material 30 is extruded over the profiled grooved strip 28 to cover the profiled grooved strip 28 to provide a co-extrusion roll-formed roof ditch molding 32, as shown in fig. 6. The co-extrusion roll formed roof ditch molding 32 is then cut to a desired length to provide roof ditch molding 34 having cut ends 36 (FIG. 8A) at the slot locations 38 (FIG. 7) to provide tabs 40 at each cut end 36. The pattern 42 of flexible material 30 is removed from the slot 24 associated with the cut end 36, as shown in fig. 7. The tab 40 is then bent to provide a final shaped end 44 of the roof ditch molding assembly, as shown in FIG. 1.
In one example, the flat metal strip 22 is made of an aluminum material. In one example, the flexible material 30 comprises a plastic material. Other types of materials may also be used to shape the strip and provide a flexible cover material.
In one example, the process begins with unwinding a thin continuous aluminum strip 50 from a roll 52, as shown in FIG. 2. For example, a thin continuous aluminum strip 50 is unwound at a constant speed. The aluminum strip 50 is passed through a leveler or leveler 54 to ensure that the strip 50 is flat to provide a flat metal strip 22 (fig. 3). Next, the continuous flat metal strip 22 is passed through a take-up ring or restrictor 56 to regulate the material flow/velocity. This allows the flat metal strip 22 to be stopped (i.e., held in place) long enough to form the notches 24 in the strip 22 while maintaining a consistent unwind rate and providing a flat slotted strip 26.
To form the slot 24, the strip 22 is fed into a hydraulic punch 58 via rollers 60 and the strip 22 is stopped/held so that the slot 24 can be punched into the strip to form the flat slotted strip 26. Thus, at this point of the process, a continuous slotted strap 26 is provided, with the slots 24 spaced along the length of the strap 26 (fig. 4). The notches 24 are pre-punched to remove excess strip material prior to any extrusion or roll forming process.
In one example shown in fig. 4, the flat grooved strip 26 has opposite side edges 62 that extend along the length L of the flat grooved strip 26 and are spaced apart from each other by the width W of the flat grooved strip 26. In one example, the notches 24 are formed in pairs in each of the opposing side edges 62 such that the pairs of notches 24 are spaced apart from one another in a first direction along the length L of the flat slotted strap 26, with the notches in each pair of notches being aligned with one another in a second direction across the width W of the flat slotted strap 26. Thus, for example, a first pair of notches 24a, 24b are aligned with one another across the width W of the strap 26, and a second pair of notches 24c, 24d are aligned with one another across the width W of the strap 26, with the first pair of notches 24a, 24b being spaced apart from the second pair of notches 24c, 24d along the length L of the strap 26.
Next, the flat slotted strip 26 passes through another take-up ring 64 that is used to regulate the flow/speed of material to the roll former 66. The strip 26 passes through guides 68 that align the strip 26 for use in a roll former 66. The strip 26 is fed into a roll former 66 and converted from a flat strip to a profiled strip 28 using a series of rollers 70 as shown in figure 5. In one example, the roller 70 is configured to convert a flat strip into a profiled strip having C-shaped sections. The C-shaped section has a base portion 72 with flanges 74 extending upwardly away from opposite edges of the base portion 72.
Next, the profiled grooved strip 28 passes through a straightener 76 which straightens the profile and directs the profiled grooved strip 28 into an extruder 78. During extrusion, a flexible material 30, such as a soft plastic skin, is, for example, overmolded over the strips 28 to cover the C-shaped sections. In one example, soft green plastic material such as thermoplastic elastomer (TPE) or Thermoplastic Polyurethane (TPU) pellets, spheres, or powder is charged into a hopper 80 and then fed into a long heated cylindrical extruder 78. The material is moved through this extruder chamber by a rotating screw (not shown) and forced into an optional metering device 82, which may be used to control the material flow. The molten plastic is forced through a small opening that includes a die 84 to shape the finished product. The profiled grooved strip 28 passes through a die 84 and a thin layer of flexible material 30, e.g., about.5 mm thick, is extruded over the C-shaped section covering the entire profiled grooved strip 28. The strip then passes through a cooling device 86. Small fins or seals (not shown) may also be formed on each side of the extrusion if desired. This forms the co-extrusion roll-formed roof ditch molding 32.
Next, the co-extrusion roll formed roof ditch molding 32 is cut to a desired length with a die cutter 88 to provide the final roof ditch molding 34 having cut ends 36, as shown in fig. 8A. In addition, the original plastic overmold is trimmed to prevent wrinkling along the edges. In one example, excess plastic material is removed in a triangular pattern 42, as shown in fig. 7. The molding 32 is then cut at the center of the slot, as indicated at 90, which forms two tabs 40. One tab 40 is for the first final roof ditch molding 34 and the other tab 40 is for the second final roof ditch molding 34. Although a triangular pattern is shown, other patterns may be used to provide different tab configurations as desired.
Thus, the die cutter 88 not only die cuts the metal but also trims away excess flexible material along the edges of the profile. When excess material is trimmed away in the triangular pattern 42, a tapered surface 92 is provided that extends from each side edge of the final roof ditch molding 34 toward the distal end of the tab 40. The die cutter 88 then makes a center cut 90 and returns to grasp the next section of the co-extrusion roll formed roof ditch molding 32. The cut pieces are then transferred to an output station 94.
After the co-extrusion roll formed roof ditch molding 32 is cut to length and excess material is removed to provide the final roof ditch molding 34, a profiled end having tabs 40 is provided, as shown in FIG. 8A. Next, the final roof ditch molding 34 is stretch-bent in a stretch bender 98 to match the contour of the vehicle roof 12, and the notch tab 40 at the end 36 of the final roof ditch molding 34 is shaped to close the end of the molding and give the vehicle 10 a highly finished appearance. In one example, the form 34 is placed in a stretch bender 98 and clamped in place. The molding 34 is then shaped to fit the contour of the roof 12. The tab 40 at the end 36 of the form 34 is then bent, for example, up to 90 degrees to provide the final formed end 44. The form 34 is then removed from the stretch bender 98.
Conventional attachment brackets, clamps and foam pieces (not shown) are still required and assembled to the molding. However, the need for a separate end cap and assembly is eliminated. Thus, the roof ditch molding 34 of the present subject matter provides a cleaner and more elegant appearance when compared to molding having an end cap. Further, bending the tab 40 to provide the final shaped end 44 results in significant cost savings.
Although specific component relationships are shown in the drawings of the present disclosure, the illustrations are not intended to limit the disclosure. In other words, the placement and orientation of the various components shown may vary within the scope of the present disclosure. In addition, the various figures accompanying this disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to show certain details of particular components.
The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Accordingly, the scope of legal protection given to this disclosure can only be determined by studying the following claims.

Claims (15)

1. A method, comprising:
cutting opposing notches in side edges of a flat metal strip to provide a flat grooved strip having pairs of notches extending along a length of the flat grooved strip;
roll forming the flat grooved strip to provide a profiled grooved strip;
extruding a flexible material to cover the profiled grooved strip to provide a roof ditch molding;
cutting the roof ditch molding at a slot location to achieve a desired molding length extending between molding cut ends including tabs, and removing a pattern of flexible material from the slot associated with the molding cut ends; and
the tab is bent to provide a final shaped end for the roof ditch molding.
2. The method of claim 1, wherein the flat metal strip has opposite side edges extending along the length of the flat metal strip and spaced apart from each other by a width of the flat metal strip, and wherein a first notch is cut in one of the opposite side edges and a second notch is cut in the other of the opposite side edges, the second notch aligned with the first notch across the width to form one pair of the notches, and wherein the other pair of notches are formed spaced apart from each other along the length to form the flat slotted strip.
3. The method of claim 1, wherein the pattern of flexible material removed from the slot comprises a triangular pattern such that a tapered surface is provided from each side edge of the roof ditch molding toward the distal end of the tab.
4. A method according to claim 3, comprising placing the roof ditch molding in a stretch bender, shaping the roof ditch molding to fit the profile of the roof, and bending the tabs at the cut end of each molding to provide the final shaped end.
5. A method, comprising:
shaping a flat metal strip;
forming a slot in the flat metal strip to provide a flat slotted strip;
roll forming the flat grooved strip to provide a profiled grooved strip;
extruding a flexible material to cover the profiled grooved strip to provide a co-extruded roll-formed roof ditch molding;
cutting the co-extrusion roll formed roof ditch molding to a desired length to provide roof ditch molding having cut ends at a slot location to provide tabs at each cut end;
removing a pattern of flexible material from the slot associated with the cut end; and
the tab is bent to provide a final shaped end for the roof ditch molding.
6. The method of claim 5, wherein the flat metal strip is made of an aluminum material and/or the flexible material comprises plastic.
7. The method of claim 5, comprising unwinding a continuous metal strip from a roll, passing the continuous metal strip through a flattening machine to provide the flat metal strip, and passing the flat metal strip through a take-up ring or restrictor to allow a downstream portion of the flat metal strip to stop for a sufficient time to form a notch in the flat metal strip while maintaining a consistent unwinding rate of the continuous metal strip.
8. The method of claim 7, comprising feeding the downstream portion of the flat metal strip into a hydraulic press to shape a slot along a length of the flat metal strip such that the flat slotted strip is shaped.
9. The method as claimed in claim 8, comprising: forming the profiled grooved strip in a roll former to have a C-shaped section profile; extruding the flexible material to form and cover the entire C-shaped section profile to form the co-extrusion roll-formed roof ditch molding; and feeding the co-extruded roll-formed roof ditch molding into a cutter.
10. The method of claim 9, wherein the pattern of flexible material removed from the cut end comprises a triangular pattern such that a tapered surface is provided from each side edge of the roof ditch molding towards the distal end of the tab.
11. The method of claim 10, comprising placing the roof ditch molding in a stretch bender, shaping the molding to fit the contour of a roof, and bending the tabs at each end of the roof ditch molding to provide a final shaped end.
12. The method of claim 5, wherein the flat metal strip has opposite side edges extending along a length of the flat metal strip and spaced apart from each other by a width of the flat metal strip, and wherein a first notch is cut in one of the opposite side edges and a second notch is cut in the other of the opposite side edges aligned with the first notch across the width to form a pair of notches, and wherein the other pair of notches are formed spaced apart from each other along the length to form the flat slotted strip, and wherein the pattern of flexible material removed from the notches comprises a triangular pattern such that a tapered surface is provided from each side edge of the roof ditch molding toward the distal end of the tab.
13. An apparatus for forming the roof ditch molding of claim 5 comprising:
a first cutter for cutting opposing notches in side edges of the flat metal strip to provide the flat grooved strip having pairs of notches extending along a length of the flat grooved strip;
a roll former that receives the flat grooved strip and roll forms the flat grooved strip to provide the profiled grooved strip;
an extruder that receives the profiled grooved strip and extrudes the flexible material to cover the profiled grooved strip to provide the roof ditch molding;
a second cutter for cutting the roof ditch molding at a slot location to achieve the desired length extending between the cut ends including the tabs and to remove the pattern of flexible material from the slots associated with the cut ends; and
a stretch bender for shaping the roof ditch molding to fit the contour of the vehicle roof and bending the tab to provide a final shaped end for the roof ditch molding.
14. A roof ditch molding, comprising:
a pre-grooved strip shaped to have a profile extending between notches provided at opposite strip ends, each end comprising a tab;
a flexible material covering the profile such that the entire pre-grooved strip is covered by the flexible material to include a roof ditch molding configured to fit along an edge of a vehicle roof;
wherein the flexible material provides a tapered surface extending from each side edge of the roof ditch molding toward the distal end of the tab; and
wherein each tab is configured to provide a curved portion that forms a finished end for the roof ditch molding.
15. The roof ditch molding of claim 14 wherein the profile includes a C-shaped profile.
CN202210420911.4A 2022-04-21 2022-04-21 Co-extrusion roll formed roof ditch molding with end forming features Pending CN116967708A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202210420911.4A CN116967708A (en) 2022-04-21 2022-04-21 Co-extrusion roll formed roof ditch molding with end forming features

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202210420911.4A CN116967708A (en) 2022-04-21 2022-04-21 Co-extrusion roll formed roof ditch molding with end forming features

Publications (1)

Publication Number Publication Date
CN116967708A true CN116967708A (en) 2023-10-31

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Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Link
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