Single piece end support for a vehicle article carrier and method of making same

1. A method of forming a one piece, cross bar end support for coupling an end of a cross bar of a vehicle article carrier system to a support rail which is secured to a vehicle outer body surface, the method comprising:

providing a mold tool having a cavity and a core member;

providing a core which is linearly movable along a first longitudinal axis for coring out a neck portion of the one piece end support, the neck portion being hollow and adapted to receive an end of a cross bar there within;

providing an additional core which is moveable in a direction opposite to the core and along a second longitudinal axis which is non-parallel to the first longitudinal axis, for coring out an intermediate portion of the one piece end support adjacent to the neck portion;

charging the mold with a molten plastic while the core and the additional core are in first positions;

waiting a predetermined time interval for the molten plastic to at least partially cure;

after the predetermined time interval has expired, then:

moving a first horn pin operably associated with the core in a direction generally perpendicular to the first longitudinal axis to cause movement of the core along the first longitudinal axis into a second position to core out the neck portion;

moving a second horn pin operably associated with the additional core to cause movement of the additional core along the second longitudinal axis, at an angle of between 30-60 degrees relative to the first longitudinal axis, into a second position to core out the intermediate portion;

the neck portion and the intermediate portion being integrally formed as a single piece component without gap lines;

further comprising using the cavity and the core component to form flange portions that extend outwardly from opposite sides of the intermediate portion, the flange portions being adapted to permit securing of the cross bar end support to the support rail; and

further comprising using another core to core out a portion of one of the flange portions.

2. The method of claim 1 , wherein moving the additional core comprises using the second horn pin engaged within an angled opening in the additional core to move the additional core along a path generally perpendicular to the direction of movement of the second horn pin.

3. The method of claim 1 , wherein moving the additional core along the second longitudinal axis comprises moving additional core along an axis that extends at about a 45 degree angle relative to the first longitudinal axis.

4. A method of forming a one piece cross bar end support for coupling an end of a cross bar of a vehicle article carrier system to a support rail secured to an vehicle outer body surface, the method comprising:

providing a mold tool having a cavity and a core member;

providing a first core which is linearly movable along a first longitudinal axis for coring out a neck portion of the one piece end support, the neck portion being hollow and adapted to receive an end of a cross bar there within;

providing a second core which is moveable along a second longitudinal axis which is non-parallel to the first longitudinal axis, and away from the first core, for coring out an intermediate portion of the one piece end support adjacent to the neck portion;

providing a third core which is moveable in a direction away from the first core, and along a third longitudinal axis parallel to the first longitudinal axis, to core out a portion of a flange of the one piece end support;

charging the mold with a molten plastic while the first, second and third cores are each in a first position;

waiting a predetermined time interval for the molten plastic to at least partially cure;

after the predetermined time interval has expired, then:

moving the first core along the first longitudinal axis into a second position to core out the neck portion to create a hollow area into which the end of the cross bar is inserted;

moving the second core away from the first core along the second longitudinal axis, the second longitudinal axis defining an angle of between 30-60 degrees relative to the first longitudinal axis, into a second position to core out the intermediate portion;

moving the third core along the third longitudinal axis, and away from the first core, into a second position to core out the portion of the flange; and

the neck portion, the intermediate portion and the flange being integrally formed as a single piece component without gap lines, and the flange formed by two portions extending outwardly in opposite directions from the intermediate portion and adapted to permit securing of the cross bar end support to the support rail.

5. The method of claim 4 , further comprising disposing a fourth core in a portion of the flange prior to charging the mold, and after the predetermined time interval, moving the fourth core in a direction opposite to a direction of movement of the third core to core out an additional portion of the flange.

6. The method of claim 5 , wherein the second longitudinal axis extends at an angle of about 45 degrees relative to the first axis.

7. The method of claim 6 , wherein the first, second and third cores are moved substantially simultaneously.

8. The method of claim 4 , further comprising:

coupling the first and third cores to a block, and using at least one horn pin to move the block parallel to the first longitudinal axis, to thus cause movement of the first core and the third core.