Unsupported ultra-flush glassrun weatherseal assembly

1. A weatherseal assembly comprising:

a generally U-shaped body including a base and first and second L-shaped legs, the first leg having a first portion that only partially overlaps with a first portion of the second leg to form the base of the U-shaped body, and the first and second legs each having a second portion extending outwardly from the first portions of the first and second legs, respectively, to form a glassrun cavity dimensioned to receive an edge of an associated window therein,

first and second seal lips extending from the first and second legs, respectively, for engagement with opposed, first and second surfaces of the associated window; and

the first leg formed entirely of a first material that is a stiffer/more rigid material than a different, second material that forms the entirety of the second leg and also forms the seal lips, such that at least a first portion of the first material forms the first leg extending outwardly from the base such that a combined thickness of the first leg and the first seal lip is less than 2.5 mm to provide a flush assembly of the weatherseal assembly and associated window.

2. The weatherseal assembly of claim 1 wherein the first portion of the first leg is dimensioned to extend only along a peripheral edge of the associated window.

3. The weatherseal assembly of claim 2 wherein the first portion of the first leg includes ridges formed therein.

4. The weatherseal assembly of claim 1 wherein the second leg includes a retention portion extending therefrom for engaging an associated shoulder of an associated vehicle component to retain the weatherseal body.

5. The weatherseal assembly of claim 4 wherein the retention portion is formed of the second material.

6. The weatherseal assembly of claim 1 wherein a cross-sectional thickness of the first leg is less than a cross-sectional thickness of the second leg.

7. The weatherseal assembly of claim 1 further comprising an adhesive for securing the first leg to the associated vehicle component.

8. The weatherseal assembly of claim 1 wherein the body has a cross-sectional profile capable of being extruded.

9. The weatherseal assembly of claim 1 wherein the second leg and second seal lip have a combined thickness greater than 2.5 mm.

10. The weatherseal assembly of claim 1 wherein the first and second legs extend parallel to one another, the first and second seal lips are formed of the second material and dimensioned to sealingly engage opposite, first and second faces of the associated window, and the base is formed in part of the both the first material and the second material, wherein the first material extends over an inner face of the base for engagement with the edge of the associated window.

11. The weatherseal assembly of claim 1 wherein the first material is an olefin-based material having a low melt index and the second material is either a thermoset or thermoplastic.

12. A method of forming a weatherseal assembly comprising:

forming a body that includes first and second L-shaped legs, the first leg includes a first portion that overlaps with a first portion of the second leg to form a base, and the first and second legs each include a second portion extending from the base that together form a body cavity dimensioned to receive an edge of an associated window;

forming the first leg entirely of a first material that is stiffer than a different, second material entirely forming the second leg;

providing first and second seal lips on the first leg and the second leg, respectively, for sealingly engaging opposite first and second surfaces of the associated window; and

dimensioning a combined thickness of the first leg and the first seal lip to be less than 2.5 mm to provide a flush assembly of the weatherseal assembly the associated window and an associated vehicle component which receives the weatherseal assembly.

13. The method of claim 12 wherein the body forming step includes coextruding the first material and second material.

14. The method of claim 12 wherein the body forming step includes extruding the first leg and at least a portion of the base from the first material, and the second leg and at least another portion of the base from the second material.

15. The weatherseal assembly of claim 12 further comprising providing an adhesive for securing the first leg to the associated vehicle component, and providing a retaining member extending outwardly from the second leg for retaining the second leg to the associated vehicle component.

16. The method of claim 15 further comprising forming the retaining member of the second material.

17. The method of claim 12 including extruding first and second seal lips on the first and second legs, respectively, for engaging opposite, first and second surfaces of the associated window.

18. The weatherseal assembly of claim 17 further comprising providing a low friction coating on the first and second seal lips.

19. The method of claim 12 further comprising dimensioning the second leg and the second seal lip to have a combined thickness greater than 2.5 mm.

20. The method of claim 12 further comprising forming the first material from an olefin-based material having a low melt index and forming the second material from either a thermoset or thermoplastic.