US 12,403,839 B2
Method of forming a one-piece vehicle roof rail
Thomas Hawkins, Spring Lake, MI (US); Paul Nikandrou, Caledonia, MI (US); Ryan Lacks, Grand Rapids, MI (US); and Nick Hrnyak, Grand Rapids, MI (US)
Assigned to LACKS ENTERPRISES, INC.
Filed by LACKS ENTERPRISES, INC., Grand Rapids, MI (US)
Filed on Jan. 31, 2024, as Appl. No. 18/427,994.
Application 18/427,994 is a continuation of application No. 16/896,739, filed on Jun. 9, 2020, granted, now 11,945,408.
Application 16/896,739 is a continuation of application No. 15/932,220, filed on Feb. 16, 2018.
Claims priority of provisional application 62/459,862, filed on Feb. 16, 2017.
Prior Publication US 2024/0217444 A1, Jul. 4, 2024
Int. Cl. B60R 9/04 (2006.01); B29C 45/16 (2006.01); B29C 45/17 (2006.01); B29C 45/37 (2006.01); B29C 48/13 (2019.01); B29C 48/154 (2019.01); B29C 48/16 (2019.01); B29C 48/18 (2019.01); B29C 45/00 (2006.01); B29K 105/04 (2006.01); B29L 31/30 (2006.01)
CPC B60R 9/04 (2013.01) [B29C 45/1642 (2013.01); B29C 45/1704 (2013.01); B29C 45/37 (2013.01); B29C 48/13 (2019.02); B29C 48/154 (2019.02); B29C 48/16 (2019.02); B29C 48/18 (2019.02); B29C 2045/0043 (2013.01); B29C 2045/172 (2013.01); B29K 2105/04 (2013.01); B29L 2031/30 (2013.01); B29L 2031/3005 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A method of forming a roof rail for a vehicle, including:
injection molding an elongated main body portion extending in a longitudinal direction between a pair of connecting portions each at an end of the main body portion, wherein the roof rail is configured to connect to the vehicle at the connecting portions, wherein the main body portion and the connecting portions are formed as a single unitary one piece component with a single upper surface being substantially continuous in the longitudinal direction, an opposing bottom surface being substantially continuous in the longitudinal direction, and two opposing side surfaces each extending between the upper and bottom surfaces, wherein the side surfaces are each substantially continuous between the upper surface and the bottom surface, and wherein the main body portion and the connecting portions are comprised entirely of a single plateable thermoplastic material with no glass filler;
wherein the roof rail is solidly filled with the single thermoplastic material an entire distance between the upper and bottom surfaces; and
electroplating a metal plating layer onto substantially an entirety of the upper surface and sides surfaces of the roof rail to provide an appearance of a metal roof rail.