A stopper and method configured to reduce potential damage to an outer lid

Abstract

A plug is disclosed for reducing the likelihood of damage to a cover or a bright strip of a weatherstrip assembly. The plug is preferably an elongate member having a first cross-sectional dimension that extends between and contacts an indented transition region of a weatherstrip body and an inner surface of a cover.

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates to an apparatus for reducing the likelihood of damage to a cover or molding of a weatherstrip assembly, and more particularly, to an insert or plug configured to be received within a cavity of a vehicle outboard assembly, and related methods for reducing and / or limiting the likelihood of damage (such as dents) to a cover or molding of a vehicle outboard assembly.

[0002] Typically, a weatherstrip assembly or weatherstrip is provided on a vehicle to seal around the perimeter of vehicle door and window openings. In many vehicles today, it is common to enhance the appearance of the weatherstrip, particularly those around window openings. For example, a weatherstrip known as an outboard is provided along the lower edge of a window opening. The outboard is secured inwardly to the vehicle, such as by using an inverted U-shaped mounting portion of the weatherstrip body that includes a clamping flange for engaging a vehicle panel. The mounting portion is often reinforced with a reinforcing member or carrier (such as a metal core) to provide additional strength and stiffness to the outboard. Extending outwardly from a first or inner surface of the body (such as along a first or inner leg of the U-shaped mounting portion) are one or more sealing lips configured to slidably and sealingly engage the surface of a window. A second leg or outer leg of the U-shaped mounting portion extends outwardly from the vehicle, thereby forming a display surface of the weatherstrip. A first shoulder is provided on the second leg, adjacent a curved portion of the U-shaped mounting portion, and a second shoulder is provided spaced apart from the first shoulder at or adjacent an end portion of the second leg. The second leg is typically configured with a transition region that defines a central indentation or bend such that an inclined portion of the second leg generally follows the vehicle profile in that region. Extending along the second leg is a cover or molding that extends generally along an elongate longitudinal extent of the outboard (i.e., along the lower edge of the window opening). The upper and lower edges of the cover operatively engage the first and second shoulders to secure the cover in an overlapping, covering relationship with the second leg of the weatherstrip. Thus, the cover and the second leg form an elongate cavity that generally extends the length of the outboard assembly.

[0003] During the process of assembling to a vehicle, or after the vehicle assembly is complete, it has been found that the cover may become dented, i.e., deformed inwardly, which is undesirable and unfortunately quite noticeable. Commonly, during assembly or after the weatherstrip is installed on a vehicle, the cover or molding (i.e., a metal such as aluminum or stainless steel) may be accidentally damaged. Thus, vehicle manufacturers and / or weatherstrip suppliers seek a solution to reduce the likelihood of damage to the weatherstrip, particularly to limit the likelihood of damage to the cover / molding during assembly and / or after the weatherstrip is installed on the vehicle.

[0004] There is a need for an improved system that addresses at least one or more of the above problems, as well as other features and benefits. Summary of the Invention

[0005] The support or plug is an elongated member having a first cross-sectional dimension that extends between and contacts the indented transition region of the weatherstrip body and the inner surface of the cover / strip.

[0006] The plug reduces potential damage to the associated cover of the associated weatherstrip assembly, the weatherstrip assembly including an associated body having a vehicle mounting portion, at least one sealing member extending from a first surface of the body, and a second surface of the body including laterally spaced-apart outward-facing first and second shoulders and an indented region disposed between the shoulders. The associated cover has a first edge and a second edge respectively mounted to the first and second shoulders of the body. When the cover is mounted to the body, a central portion of the cover is spaced from the indented transition region of the body and a cavity is formed therebetween that extends along the longitudinal dimension of the body, and the plug is received in the cavity.

[0007] In one form, the elongated member has a cylindrical outer surface and more particularly may include a central opening to form a hollow cylindrical configuration.

[0008] In another embodiment, the elongated member is integrally formed with the associated body of the weatherstrip. The elongated member may include a first end integrally connected to the associated body and a bifurcated second end adjacent to the inner surface of the cover.

[0009] The elongated member may include a circular protrusion having a profile dimension for mating reception with the indented transition region of the body.

[0010] The elongated member may include a circular profile surface located on either side of the circular protrusion, the circular protrusion sized to selectively abut the clamping region and the angled region of the second leg respectively.

[0011] Additional circular protrusions may be provided and sized for selective abutment with the inner surface of the cover.

[0012] In another embodiment, a first extension member and a second extension member project laterally from opposite regions of the elongated member, and the first and second extension members are sized for reception in notch profiles of the first and second shoulders respectively.

[0013] In yet another embodiment, the elongated member includes a groove that matingly receives a central co-extruded extension extending from the transition region of the second leg.

[0014] A method of forming an elongate member that reduces potential damage to an associated cover of an associated weatherstrip assembly, the method including sizing the elongate member to have a first cross-sectional dimension that extends between and contacts an indented transition region of a body and an inner surface of a cover.

[0015] The forming step may include extruding the elongate member.

[0016] The method may also include providing a locating portion on a second leg for receiving a protrusion on the elongate member.

[0017] A method of forming another embodiment includes forming a lateral extension on the elongate member sized to be received under a first shoulder and a second shoulder.

[0018] The method includes inserting a first lateral extension under a first shoulder and subsequently snapping a second lateral extension under a second shoulder to locate the elongate member in a cavity.

[0019] The benefits and advantages of the present disclosure will become more apparent by reading and understanding the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a front view of a vehicle door.

[0021] Figure 2 is a sectional view taken generally along line 2–2 Figure 1 without including the support plug of the present invention.

[0022] Figure 3 is a sectional view substantially similar to Figure 2 (rotated 180°) and including a form of the support plug of the present invention.

[0023] Figure 4 is a sectional view of a second preferred arrangement of the support plug.

[0024] Figure 5 is a sectional view of a third preferred arrangement of the support plug.

[0025] Figure 6 is a sectional view of a modified fourth form of the third preferred arrangement of the support plug.

[0026] Figure 7 is a sectional view of a fifth form of the support plug.

[0027] Figure 8 is a sectional view of a sixth form of the support plug.

[0028] Figure 9 is a sectional view of a seventh embodiment of the support plug.

[0029] Figure 10 It is a cross-sectional view of the eighth embodiment of the support plug.

[0030] Figure 11 It is a cross-sectional view of the ninth embodiment of the support plug. Detailed implementation manners

[0031] The following description with reference to the accompanying drawings is to assist in a comprehensive understanding of one or more embodiments of the present disclosure defined by the claims and their equivalents. It includes various specific details to assist in the understanding, but these details are only regarded as exemplary. Therefore, those of ordinary skill in the art will recognize that various changes and modifications can be made to the various embodiments described herein without departing from the spirit and scope of the present disclosure. The various exemplary embodiments of the present disclosure are not limited to the specific details of different embodiments and should be understood to include all changes and / or equivalents or alternatives within the spirit and technical scope of the appended claims. When describing the drawings, like reference numerals are used to represent like elements whenever possible.

[0032] The term "comprising" or "may comprise" used in the present disclosure indicates the presence of the corresponding functions, operations, elements, etc. disclosed, and does not limit the additional one or more functions, operations, elements, etc. In addition, it should be understood that the terms "comprising", "including", "having" or "with" used in the present disclosure indicate the presence of the components, features, quantities, steps, operations, elements, components or combinations thereof described in the specification, and do not exclude the presence or addition of one or more other features, quantities, steps, operations, elements, components or combinations thereof.

[0033] The term "or" or "at least one of A or / and B" used in the present disclosure includes any and all combinations of the words listed therewith. For example, "A or B" or "at least one of A or / and B" means including A, including B, or including both A and B.

[0034] Although terms such as "first" and "second" used in the present disclosure may modify various elements of different exemplary embodiments, these terms do not limit the corresponding elements. For example, these terms do not limit the order and / or importance of the corresponding elements, and these terms also do not exclude additional elements (e.g., second, third, etc.). These terms can be used to distinguish one element from another. For example, the first mechanical device and the second mechanical device both represent mechanical devices, and can represent different types of mechanical devices or the same type of mechanical device. For example, without departing from the scope of the various exemplary embodiments of the present disclosure, the first element can be named the second element, and similarly, the second element can be named the first element.

[0035] It should be understood that when an element is referred to as being "connected" or "coupled" to another element, the element can be directly connected or coupled to the other element, or there can be an intermediate element between the element and the other element. Conversely, it should be understood that when an element is referred to as being "directly connected" or "directly coupled" to another element, there is no intermediate element between the element and the other element.

[0036] The terms used in the various exemplary embodiments of the present disclosure are for the purpose of describing specific exemplary embodiments only and are not intended to limit the various exemplary embodiments of the present disclosure. As used herein, the singular forms are also intended to include the plural forms unless the context clearly indicates otherwise.

[0037] The meaning of all terms used herein (including technical or scientific terms) is the same as that commonly understood by those of ordinary skill in the relevant art, unless they are otherwise defined. Terms defined in commonly used dictionaries should be interpreted as having the same meaning as the context of the relevant art and should not be interpreted as having inconsistent or exaggerated meanings unless they are clearly defined in the various exemplary embodiments.

[0038] Turning to Figure 1 , a portion of the vehicle 100 is shown in the figure, particularly the door 102. An opening 104 is provided in the door 102, and the opening is selectively closed or opened by raising and lowering the window 106. The specific details of the structure and operation of the window 106 and the installation of the window in the door 102 are well known in the art and thus need not be further described herein to fully and completely understand the present disclosure.

[0039] A weatherstrip assembly or weatherstrip 120 is provided and engaged between the door opening 104 and the peripheral portion of the window 106. In addition to providing an aesthetic transition between the door 102 and the window 106, the weatherstrip 120 also provides a seal between the interior and exterior environments of the vehicle. The weatherstrip 120 can be manufactured and / or assembled as one or more components and generally provides a peripheral sealing function adjacent to the A-pillar, which is represented herein by the mirror sail portion 122, the roof portion 124, and the B-pillar portion 126. These three weatherstrip portions 122, 124, 126 can be formed as a generally U-shaped component, the inner and outer legs of which are interconnected by a base or curved portion, jointly forming a groove that receives the corresponding outer peripheral portion of the window 106 in these regions of the weatherstrip 120 in the window closed position.

[0040] Along the lower portion of the window opening 104, the weatherstrip 120 generally includes an inner band / inner band portion (not shown) and an outer band / outer band portion 130. Thus, as Figure 1As shown, the outer strip 130 extends longitudinally (from the front to the rear of the vehicle) along the lower edge of the door opening 104 between the A-pillar / mirror sail and the B-pillar. More specific details of the outer strip 130 are shown in Figure 2 which is shown in. Preferably, the outer strip 130 is constructed to be extrudable, i.e., the outer strip has a cross-sectional profile that allows for the formation of a continuous, elongated weatherstrip profile and is subsequently cut to a certain length (i.e., Figure 1 the length shown in), and advantageously provides the desired attachment, sealing, and aesthetic transition functions for the outer strip portion of the weatherstrip 120.

[0041] The outer strip 130 of the weatherstrip assembly 120 includes a body 132 formed of an extruded material, such as any one or more of the conventional elastomeric, rubber, or plastic materials used in the industry. The outer strip body 132 is constructed to form a mounting portion 134, which in the form shown in this particular illustration includes an inverted U-shaped cross-sectional structure having a first leg or inner leg 136, a second leg or outer leg 138, and an interconnecting base 140. Although the specific construction of these components can vary, generally the first leg 136 has a substantially linear construction, while the second leg 138 includes a linear clamping region 138a and an angled region 138b that extends along the outer surface of the door 102. To facilitate the installation or attachment of the outer strip 130 to the door 102, the inner surface of the first leg 136 and the linear clamping region 138a of the second leg 138 may include clamping flanges 142, which also frictionally engage a door flange (not shown) in a manner conventionally known in the art and thus do not need to be further discussed herein. To increase the strength and stiffness of the outer strip in the mounting portion 134, the body may include a carrier or support 150 that is encapsulated or at least partially encapsulated by the body material during the extrusion process, such as metal or rigid plastic. The carrier 150 is typically deformed or bent into the desired inverted U-shape and the body material is extruded over it to at least partially or completely encapsulate the carrier. On the other hand, the clamping flanges 142 may be formed of the same material as the rest of the extruded body or may be a different material that enhances the clamping function. Additionally, deformable sealing protrusions 154 may be provided at spaced-apart positions along the first leg 136 and the second leg 138 for engaging the door 102.

[0042] At least one sealing member (shown herein as a pair of sealing lips 160) extends outwardly from the first surface of the body 132. As Figure 2 shown, the first and second sealing lips 160 are preferably co-extruded with the rest of the body and extend outwardly from the first surface of the first leg 134 for engaging the window 106 ( Figure 2(not shown in the figure) engage. The sealing lip 160 may include a low-friction material 162 that slidably and sealingly engages the outer surface of the window 106. The second surface of the body 132 includes an outward-facing first shoulder 170 and a second shoulder 172, which are laterally spaced apart on opposite sides of an indentation region formed by a transition 138c between a linear mounting region 138a and an angled region 138b of the second leg 138. The profiles of the first shoulder 170 and the second shoulder 172 are configured to receive or mount the laterally spaced longitudinal edges of a cover or molding 180. When the cover / molding 180 is fixed to the body (i.e., the shoulders 170, 172), the central portion of the cover is mounted in a spaced relationship from the transition region 138c of the second leg 138 of the body 132, thereby forming a cavity 182 therebetween that extends along the longitudinal dimension of the body. As Figure 2 shown, in this arrangement, the cover 180 has a relatively wide and relatively slender unsupported span, which is thought to contribute to the likelihood of the cover / molding being dented or damaged during assembly or after installation on a vehicle. Unfortunately, this results in undesirable repair costs.

[0043] Various possible solutions have been proposed to address potential damage to the outer molding / cover 180. Referring Figure 3 to, the same reference numerals are used to describe the same components previously described in connection with Figure 2 the description, while new numerals are used to describe new components associated with a preferred solution for potential damage to the cover / molding 180. As Figure 3 shown, an elongate hollow cylindrical support or plug 200 is provided and disposed within the cavity 182. Preferably, the plug 200 has a relatively thin wall 202 while still maintaining sufficient stiffness to support the inner surface of the central region of the molding 180, preferably at a location generally opposite the transition 138c. The hollow circular plug 200 provides the desired support and reduces the unsupported length of the molding 180 by providing a member that engages the transition region of the cover / molding and the weatherstrip. Unfortunately, due to the asymmetric shape of the internal cavity 182 beneath the cover 180, the cylindrical plug 200 may be considered relatively inconsistent in application.

[0044] In Figure 4 , the support 210 is integrally formed with the remainder of the body and extends outwardly from the second leg 138. The support 210 preferably includes a bifurcated end 212 that engages the inner surface of the cover / molding 180 at spaced-apart first and second locations. The support 210 has the advantage of being easy to manufacture, and the support can be co-extruded like other parts of the body 132 (such as the shoulders 170, 172, the sealing lip 160, the retaining flange 142, etc.). Of course, those skilled in the art will recognize that the support plug 210 can also be formed as a separate component and subsequently inserted into the cavity 182, asFigure 4 Alternative integrated co-extruded forms are shown without departing from the scope and intent of the present disclosure.

[0045] Figures 5 - 11 The different embodiments regarding the support or plug 220 have similarities to each other. As Figure 5 shown, the plug 220 has a generally solid cross-section, and in particular, a unique outer design profile that helps to position or set the plug within the cavity 182. The enlarged protrusion 222 has a smooth, rounded convex profile that, for example, generally matches the profile of the transition 138c of the second leg 138 of the outer weatherstrip 130. Additionally, the smaller rounded profile surface 224 is adapted to engage the straight portion 138a and the angled portion 138b of the second leg, respectively. The other side of the plug 220 preferably includes a plurality of protrusions or rounded surfaces 226 that are spaced apart from each other and engage different spaced-apart inner surface regions of the bright strip, which are generally opposite the inner surface region of the transition 138c. This configuration of the plug 220 can be extruded as a separate component and longitudinally inserted into the cavity 182.

[0046] As Figure 6 shown, the orientation of the separately formed plug 230 can be determined by adding orientation features such as tabs 232. Additionally, an additional co-extruded extension 234 can project outward from the body to further position and orient the plug 230 within the cavity 172. Thus, the plug 230 includes an enlarged protrusion 222 that mates with the transition region 138c of the second leg 138 of the outer strip 130, as well as a rounded profile surface 224 designed to engage adjacent portions of the second leg and rounded protrusions 226 that engage the inner surface of the cover / bright strip 180 opposite the second leg.

[0047] In Figure 7 , the plug 240 has some similarities to the plugs shown and described in Figures 5 - 6 . The plug 240 includes orientation tabs 232 as well as rounded protrusions 222, 224, 226. The main difference between the plug 240 and the plugs 220, 230 of Figure 5 and Figure 6 is the central hollow region 242 to reduce the material usage and total weight of the modified plug. However, it is apparent that the hollow region 242 generally follows the outer profile of the plug 240 such that the plug has a generally constant wall thickness to obtain the desired strength and stiffness.

[0048] Figure 8 Illustrated is a plug 250 that incorporates selected features from the embodiments in the foregoing Figure 3 , Figure 6 and Figure 7 . Specifically, the face of the plug 250 facing the transition region 138c of the second leg 138 has the same asFigure 3 a substantially hollow cylindrical portion similar to the hollow cylindrical plug 200 in Figures 6 - 7 In addition, a plurality of circular protrusions 226 are provided on a portion of the plug that engages the inner surface of the cover / bright strip 180 opposite the transition region 138c in a manner similar to the

[0049] Figure 9 plug 260 employs features similar to the Figure 7 plug 240 embodiment; however, it includes a centrally co-extruded extension 262 that extends from the transition region 138c of the second leg 138 and that is received in a mating groove 264 in the plug 260. The interconnection of the extension 262 and the groove 264 provides for accurate, repeatable positioning of the plug 260 within the cavity 182.

[0050] Finally, referring to Figure 10 and 11 , slightly different variants of the plugs 270 ( Figure 10 ) and plugs 280 ( Figure 11 ) are shown. Outwardly extending lateral members or wings 272 project laterally from opposite regions of the plugs 270 or 280 for receipt in the notched profiles of shoulders 170, 172 that extend from the second leg 138 of the outer band body 132. One of the extending wings 272 can be received below the notched profile of one of its associated shoulders 170, 172 and then the other of the extending wings 272 can snap below the notched profile of the other shoulder 172, 170. Thus, in a preferred method of assembly, one of the wings 272 is inserted into the cavity 182 and below one of the shoulders 170, 172. Thereafter, the plug 270 or plug 280 is rotated such that the other wing 272 snaps below the other shoulder 172, 170. This provides the desired installation accuracy, provides a tactile feedback that the plug has been installed during assembly, positions the plug within the cavity of the weatherstrip, and ensures repeatability during assembly, as well as repeatability and performance after assembly. It should be understood that Figure 10 and Figure 11Variations of the structure shown. For example, alternative plugs can be envisioned that eliminate the hollow central opening, or provide some of the same or more rounded profiled surfaces 226 to engage the linear portion 138a and angled portion 138b of the second leg, respectively, or the other side of the plug 220 can include or not include a plurality of protrusions or rounded surfaces 226, or different numbers or configurations of protrusions, etc., without departing from the scope and intent of the present disclosure. Preferably, the profile on the elongate member defining the plug will advantageously have a cross-sectional profile that achieves the desired support function and is also easily extruded for ease of manufacture. Preferred exemplary materials for forming the plug include elastomers, plastics, or combinations of these materials. The preferred material for the plug provides the required support for the cap / bright strip and can be easily extruded as a separate plug or co-extruded with other parts of the weatherstrip assembly. Of course, this list of materials is not exhaustive, and other materials can still be used to form the plug, e.g., materials that are economical to use, easy to extrude, and capable of maintaining the desired support of the cap / bright strip.

[0051] Although these preferred devices and preferred methods outline the desired construction or sequence of the various steps, those skilled in the art will understand that other combinations of device features or method steps can still be included, or some device features or method steps can be omitted, or another sequence of one or more steps can be provided.

[0052] This specification uses examples to describe the invention, including the best mode, and also enables any person skilled in the art to make and use the invention. Other examples that occur to those skilled in the art are intended to be within the scope of the invention if they have structural elements that do not differ from the same concept or from the literal language of the claims, or if they include equivalent structural elements that do not differ materially from the same concept or from the literal language of the claims. Additionally, this disclosure is intended to seek protection for the combination of components and / or steps and the combination of claims as initially filed for review, as well as for other combinations of components and / or steps and claims during prosecution.

[0053] Although specific advantages have been listed above, various embodiments can include some, none, or all of the listed advantages. Although exemplary embodiments have been illustrated in the drawings and described herein, any number of techniques can be used to implement the principles of the present disclosure, whether currently known or not. Additionally, the operation of the systems and devices disclosed herein can be performed by more, fewer, or other components, and the methods described herein can include more, fewer, or other steps. Further, the steps can be performed in any suitable order.

[0054] To assist the Patent Office and any readers of this application and any resulting patent in understanding the appended claims, the applicant does not intend for any of the appended claims or claim elements to invoke 35 USC 112(f), unless the terms "means" or "step" are expressly used in a particular claim.

[0055] List of Components

[0056] 100 Vehicle

[0057] 102 Door

[0058] 104 Door Opening

[0059] 106 Window

[0060] 120 Weatherstrip Assembly / Weatherstrip

[0061] 122 A-Pillar / Mirror Sail Portion

[0062] 124 Roof Portion

[0063] 126 B-Pillar Portion

[0064] 130 Outer Belt Portion / Outer Belt

[0065] 132 Body

[0066] 134 Mounting Portion

[0067] 136 First / Inner Leg

[0068] 138 Second / Outer Leg

[0069] 138a Linear Clamping Region

[0070] 138b Angled Region

[0071] 138c Transition Region

[0072] 140 Interconnecting Base

[0073] 142 Clamping Flange

[0074] 150 Carrier / Support

[0075] 154 Sealing Protrusion

[0076] 160 Sealing Lip

[0077] 162 Low-Friction Material

[0078] 170 First Shoulder

[0079] 172 Second Shoulder

[0080] 180 Cover / Trim

[0081] 182 cavities

[0082] 200 Support / Stopper

[0083] 202 Thin Wall

[0084] 210 Support / Stopper( Figure 4 )

[0085] 212 Forked End

[0086] 220 Support / Stopper( Figure 5 )

[0087] 222 Enlarged Protrusion

[0088] 224 Circular Contour Surface

[0089] 226 Protrusion / Circular Surface

[0090] 230 Support / Stopper( Figure 6 )

[0091] 232 Orientation Feature / Tab

[0092] 234 Co-extruded Extension

[0093] 240 Support / Stopper( Figure 7 )

[0094] 242 Central Hollow Area

[0095] 250 Support / Stopper( Figure 8 )

[0096] 260 Support / Stopper( Figure 9 )

[0097] 270 Support / Stopper( Figure 10 )

[0098] 272 Extended Lateral Member / Fin

[0099] 280 Support / Stopper( Figure 11 )

Claims

1. A weatherstrip assembly, comprising: a body having a vehicle mounting portion, at least one sealing member extending from a first surface of the body, and a second surface of the body, the second surface including laterally spaced-apart outwardly facing first and second shoulders and an indentation region disposed between the first and second shoulders; a metal cover having a first edge and a second edge respectively mounted to the first and second shoulders of the body such that a central portion of the metal cover is spaced from the indentation region of the body and a cavity is formed between the metal cover and the indentation region extending along a longitudinal dimension of the body; a plug including an elongate member separated from the body and separated from the metal cover, the plug being located in the cavity between the first and second shoulders of the body and axially extending along the longitudinal dimension of the body within the cavity, the plug having a first cross-sectional dimension extending between and in contact with the indentation region of the body and an inner surface of the metal cover such that the plug supports the metal cover relative to the body to reduce potential damage to the metal cover; wherein the elongate member includes a protrusion sized to matingly receive with the indentation region of the body; the weatherstrip assembly further includes first and second extension members laterally protruding from opposite regions of the elongate member, the first and second extension members being sized to respectively be received in notch profiles of the first and second shoulders.

2. The weatherstrip assembly according to claim 1, wherein the elongate member further includes a circular profile surface located on opposite sides of the protrusion, the circular profile surface being sized to selectively abut a clamping region of the second surface on a first side of the indentation region and an angled region of the second surface on a second side of the indentation region.

3. The weatherstrip assembly according to claim 2, wherein the elongate member further includes an additional circular protrusion positioned and sized to selectively abut an inner surface of the metal cover.

4. The weatherstrip assembly according to claim 1, further including a central opening in the elongate member.

5. The weatherstrip assembly according to claim 1, wherein the elongate member of the plug includes a groove that matingly receives a central co-extruded extension extending from the indentation region of the second surface.

6. A method of limiting potential damage to a metal cover of a weatherstrip assembly, the weatherstrip assembly including a body having a vehicle mounting portion, at least one sealing member extending from a first surface of the body, and a second surface of the body, the second surface including laterally spaced-apart outward-facing first and second shoulders and an indentation region disposed between the first and second shoulders, the metal cover having a first edge and a second edge respectively mounted to the first and second shoulders of the body such that a central portion of the metal cover is spaced from the indentation region of the body and a cavity extending along a longitudinal dimension of the body is formed between the metal cover and the indentation region of the body, the method comprising: forming an elongate support plug member separate from the body and separate from the metal cover; and positioning the elongate support plug member in the cavity between the first and second shoulders of the body such that the elongate support plug member extends along the longitudinal dimension of the body within the cavity, and sizing the elongate support plug member to have a first cross-sectional dimension extending between and contacting the indentation region of the body and an inner surface of the metal cover to support the metal cover and reduce potential damage to the metal cover; wherein the step of forming the elongate support plug member includes forming a first laterally extending portion and a second laterally extending portion on the elongate support plug member; and wherein the step of positioning the elongate support plug member in the cavity between the first and second shoulders of the body includes positioning the first laterally extending portion and the second laterally extending portion of the elongate support plug member respectively under the first and second shoulders of the body.

7. The method according to claim 6, wherein the forming step includes extruding the elongate support plug member.

8. The method according to claim 6, further comprising providing a positioning portion on the second surface of the body for engaging corresponding protrusions formed on the elongate support plug member.

9. The method according to claim 6, wherein the step of positioning the elongate support plug member in the cavity further includes inserting the first laterally extending portion under the first shoulder and then snapping the second laterally extending portion under the second shoulder to position the elongate support plug member in the cavity.

10. The method according to claim 7, further comprising providing a central opening through the elongate support plug member during the step of extruding the elongate support plug member.

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