Abstract: An elongate core metal insert for reinforcing a resilient weatherseal includes a main body portion extending along a longitudinal axis, opposed first and second edges, and opposed first and second face surfaces extending between the first and second edges. A plurality of flutes are formed into the first and second face surfaces of the core metal insert in an undulating pattern, and extend between the first and second edges such the core metal insert is corrugated. The corrugation of the core metal insert separates the first and second face surfaces by a distance greater than the original thickness of the core metal insert. A method of providing such a core metal insert also is provided.

Abstract: An elongate core metal insert for reinforcing a resilient weatherseal includes a main body portion extending along a longitudinal axis, opposed first and second edges, and opposed first and second face surfaces extending between the first and second edges. A plurality of flutes are formed into the first and second face surfaces of the core metal insert in an undulating pattern, and extend between the first and second edges such the core metal insert is corrugated. The corrugation of the core metal insert separates the first and second face surfaces by a distance greater than the original thickness of the core metal insert. A method of providing such a core metal insert also is provided.

Abstract: A core metal insert is provided having a series, or multiple series, of laterally extending score marks in a non-reduced thickness portion, or portions, of the insert. Such score marks are provided in at least one face surface of the insert. The score marks provide stress relief so that when the corresponding precursor sheet metal blank is lengthened to produce the insert, the resulting insert will have a lesser tendency to contract from its lengthened state. A method of providing such a core metal insert also is provided.

Abstract: A core metal insert is provided for reinforcing a weatherseal. The core metal insert has a generally U-channel shaped cross-section and has first and second tines extending from a longitudinally extending backbone strip. The tines are bent to provide the U-channel shaped cross-section. The backbone strip is preferably double-coined to provide first and second grooves, one along each face of the backbone strip. Double coining results in greater length extension of the core metal insert, and also provides for more reliable bending of the tines which are less prone to snap off due to bending stress. Preferably, the backbone strip is provided with a plurality of score marks on both of its opposing faces to facilitate reliable and consistent severance of the backbone strip along the score marks to provide discrete structural staples in the weatherseal.

Abstract: A core metal insert is provided for reinforcing a weatherseal. The core metal insert has a generally U-channel shaped cross-section and has first and second tines extending from a longitudinally extending backbone strip. The tines are bent to provide the U-channel shaped cross-section. The backbone strip is preferably double-coined to provide first and second grooves, one along each face of the backbone strip. Double coining results in greater length extension of the core metal insert, and also provides for more reliable bending of the tines which are less prone to snap off due to bending stress. Preferably, the backbone strip is provided with a plurality of score marks on both of its opposing faces to facilitate reliable and consistent severance of the backbone strip along the score marks to provide discrete structural staples in the weatherseal.

Abstract: An elongate metal insert or carrier for reinforcing a weatherseal having a covering of flexible material. The metal insert has opposed and longitudinally extending first and second edges. A plurality of longitudinally spaced apart first slots transversely extend from the first edge and a plurality of longitudinally spaced apart second slots transversely extend from the second edge in an alternating manner. The second slots are longitudinally offset from the first slots and transversely overlap the first slots. A longitudinally extending continuous connection interrupts the second slots and is offset from the centerline of the insert. The continuous connection defines the neutral axis of the weatherseal which does not permit expansion or contraction and therefore prevents shrinkage of the weatherseal at that point. The continuous connection, and therefore the neutral axis, is preferably located adjacent a sealing member to reduce bulb roll over or lip flattening problems.