Method of Making A Top Stack Linkage With an Injection Molded Magnesium Link

Abstract

A link of a top stack linkage for a convertible top of a vehicle is presented for immediate incorporation in a top stack linkage. The link is molded as a spine having a main body portion and an offset portion, and one or more lateral structural members including at least one reinforcing rib. The molding forms a unitary pivot link, installed in the top stack linkage as molded, to reduce finishing of the parts, and reducing fabrication time and linkage weight from known top stack linkage configurations. A method of manufacturing includes providing a mold defining an interior cavity that defines the shape of a pivot link, injecting molten magnesium into the mold, and molding the molten magnesium to form a spine and at least one of a plurality of lateral structural members that form a monolithic pivot link.

1 . A method of manufacturing a pivot link of a top stack linkage for a convertible top of a vehicle, the method comprising:
 providing a mold defining an interior cavity that defines the shape of a pivot link;   injecting molten magnesium into the mold;   molding to form a monolithic link;
 the magnesium injected into the mold to form a spine, and 
 molding to form a plurality of lateral structural members that are integral with the spine to form a monolithic link. 
   
     
     
         2 . The method of  claim 1  wherein the molding step further comprises molding the spine to include a main body portion and at least one offset portion relative to a plane of the main body portion. 
     
     
         3 . The method of  claim 1  wherein the lateral structural members include a plurality of reinforcing ribs and the molding step further comprises molding the plurality of reinforcing ribs to reinforce the pivot link, the spatial orientation of the offset portion relative to the main body portion. 
     
     
         4 . The method of  claim 1  wherein the pivot link includes a front portion and a back portion that define planar flange portions of the pivot link and the molding step further comprises forming the planar flange portions for permitting a plurality of adjacent links to pivot relative to the pivot link. 
     
     
         5 . The method of  claim 1  wherein the plurality of lateral structural members includes a plurality of pins disposed at spaced locations on the spine and the method further comprises connecting a plurality of links and a plurality of bows to the pivot link. 
     
     
         6 . The method of  claim 1  wherein the plurality of lateral structural members includes a plurality of bushings disposed at spaced locations on the spine, the plurality of bushings being reinforced by a plurality of radially extending ribs interconnected by circumferentially extending ribs, and the method further comprises inserting a plurality of pins in the plurality of bushings for connecting adjacent links to the pivot link. 
     
     
         7 . A method of manufacturing a top stack linkage with a molded pivot link for operating the top stack linkage for a convertible top of a vehicle, the method comprising:
 providing a mold defining an interior cavity that defines the shape of a pivot link;   injecting molten magnesium into the mold;   molding to form a spine,   molding to form a plurality of lateral structural members that are integral with the spine to form a monolithic link, and   assembling the pivot link within the top stack linkage upon removal from the interior cavity.   
     
     
         8 . The method of  claim 7  wherein the molding step further comprises molding the spine to include a main body portion along a first plane and at least one offset portion offset relative to the first plane of the main body portion. 
     
     
         9 . The method of  claim 7  wherein the lateral structural members include a plurality of reinforcing ribs. 
     
     
         10 . The method of  claim 7  wherein the molding step further comprises molding the plurality of reinforcing ribs to reinforce the spatial orientation of the spine offset portion relative to the spine main body portion. 
     
     
         11 . The method of  claim 7  wherein the molding step further comprises forming at least one planar flange portion for permitting a plurality of adjacent links in the top stack linkage to pivot relative to the pivot link. 
     
     
         12 . The method of  claim 7  wherein the plurality of lateral structural members includes molding a plurality of pins disposed at spaced locations on the spine and further comprises connecting a plurality of links in the top stack linkage and a plurality of bows in the top stack linkage to the pivot link. 
     
     
         13 . The method of  claim 7  wherein the plurality of lateral structural members includes molding a plurality of bushings disposed at spaced locations on the spine, the plurality of bushings being reinforced by molding a plurality of radially extending ribs interconnected by circumferentially extending ribs, and further comprises inserting a plurality of pins in the plurality of bushings for connecting adjacent links in the top stack linkage to the pivot link.