Hybrid header for convertible top

摘要

A hybrid convertible top header is formed of a transverse steel tube flattened at its ends and having end fittings for attachment to the front ends of top front side rails. In one embodiment a pair of apertured latch-mounting steel plates are welded to the tube and the entire steel structure is encapsulated in a thermoplastic shroud comprising upper and lower moldings that are bonded along front and rear flanges. The top cover is secured to the front flange, while a closed or open cell foam pad is mounted on the rear flange to provide an energy-absorbing cushion in case of occupant impact on the header. In another embodiment, the plates are not welded to the tube, and the tube and plates are molded into a closed or open cell reaction injected molded polyurethane body that has sufficient rigidity to maintain a predetermined dimensional relationship between the plates and tube. The polyurethane body is also sufficiently soft to provide sufficient energy absorption in the event of occupant impact to meet FMVSS requirements. In a variant of this embodiment, the energy-absorbing segment can be of different density than the main body.