Abstract: Sheet molding composition formulation includes a thermoset cross-linkable polymeric resin. A moisture reducing polymeric additive includes at least one of polystyrene; poly C1-C4 alykylmethacrylate; a copolymer of styrene with at least one of butadiene, acrylonitrile and vinyl chloride; or a combination of polystyrene, polyaklymethacrylate and or a styrene copolymer. Moisture reducing polymeric additive is present within the formulation from between 1 and 20 total weight percent. An article formed from such a sheet molding composition formulation defines an article shape and has a surface that sets the article shape with less than 0.5 total weight percent water after 96 hours exposure and 100° F. 100% humidity. The article shape is amendable to receiving a vapor barrier coating applied to the articles shape surface. A powder prime coating over lies the barrier coating and achieves surface finish results comparable to article shapes formed of steel.

Abstract: Vacuum assisted molding apparatus provides reliable sealing about the mold cavity while minimizing the area of the plant floor space occupied by the mold. The apparatus includes an upper die, a lower die, a vacuum source, and a sealing assembly. The upper die includes a generally horizontal molding surface and vertically extending sides. The lower die includes a generally horizontal molding surface cooperating with the upper die to form a mold cavity. The sealing assembly is operable to create a vacuum surrounding the mold cavity.

Abstract: A molding compound contains a reinforcing fiber, a non-fibrous filler, and an unsaturated polyester resin. The unsaturated polyester resin contains an unsaturated monomer as well as a polyester polymer. The polymer is a unsaturated polyester made from a hydroxyl component and a carboxylic component. The hydroxyl component contains both a monomeric diol or triol, and a polymeric polyol. The polymeric polyol is a hydroxyl-terminated polymer such as polyether or polyester diols or triols. The carboxylic component can be provided by an unsaturated carboxylic diacid, an unsaturated carboxylic anhydride, an unsaturated carboxylic diester or mixtures thereof. Molded articles are provided by compression or extrusion molding of a molding compound as described above. The articles are characterized by improved crack resistance, toughness, and surface appearance.

Abstract: A method for adhesively joining two members includes the steps of mixing non-compressible beads with an adhesive, applying the resulting mixture to one of the members and hemming one member over the other in overlapping relationship. Apparatus for performing this method includes a container for containing a mixture of an adhesive and a plurality of non-compressible beads, an applicator for applying the mixture to one of the members, and hemming means for hemming one member over the other in overlapping relationship. A metering device for dispensing adhesive fluid is constructed with a dispensing rod having a cooling means for facilitating operation of the metering device. The present invention finds particular utility in bonding together the inner and outer panels of an automotive door assembly.

Abstract: A method of fabricating a vehicle door includes providing a lower door structure, providing an upper door structure having a pair of spaced apart frame rails, installing a window member between the frame rails, installing a window regulator to the window member and the upper door structure, and coupling the lower and upper door structures to one another. The window regulator may include a powered lead screw regulator, a rack and pinion regulator or a cable and drum regulator.

Abstract: A tonneau cover attachment system for a motor vehicle having a cargo area defined by a first side wail having a stake pocket includes a first plate and a second plate. The first plate has a first end and a second end and is positioned within the stake pocket. The second plate has a first end and a second end. The second end of the second plate is coupled to the second end of the first plate. The first end of the first plate is coupled to the first end of the second plate.

Abstract: A motor vehicle for transporting passengers includes a body defining a passenger compartment, a first row of seats positioned within the passenger compartment, a second row of seats positioned within the passenger compartment rearward of the first row of seats, and a third row of seats positioned within said passenger compartment rearward of said second row of seats. The second and third rows of seats have seat backs and a seat bottoms. A first door is hingedly coupled to the vehicle for providing access to the first row of seats. A second door is positioned rearward and adjacent to the first door. The second door selectively encloses an opening formed in the body. The opening extends from a point forward of the seat bottom of the second row of seats to a point at least partially exposing the seat bottom of the third row of seats.

Abstract: A closure assembly for a vehicle includes an outer panel and an inner panel. The outer panel has an exterior surface and an opposed bonding surface. The inner panel has an interior surface and an opposed mounting surface The mounting surface of the inner panel and the bonding surface of the outer panel are coupled at their periphery to form a shell. The shell defines a pocket. An electrical device may be positioned within the pocket and coupled to one of the inner and outer panels In one embodiment, a majority of the interior surface of the inner panel is exposed to the passenger compartment. In another embodiment, the inner panel includes an integrally molded wire to conduct electricity to the electrical device.

Abstract: A frame assembly is provided for a vehicle. The frame assembly includes a pair of frame rails and a subframe disposed between the frame rails. The subframe includes a unitary, generally U-shaped cradle including a front cross member and a pair of side members extending from the front cross member. A pair of front attachment members extend from a front portion of the cradle and attach to the frame rails. A pair of rear attachment members extend from a rear portion of the cradle and attach to the frame rails.

Abstract: A bumper for a motor vehicle having a tonneau cover moveable from an opened position to a closed position includes an annular body having an inner surface and an outer surface where the inner surface defines a bore. The bumper also includes a rib extending from a first position on the inner surface to a second position on the inner surface within the bore. The bumper is adapted to be mounted to the vehicle and positioned between the tonneau cover and the vehicle when the tonneau cover is in the closed position.

Abstract: A door includes a door shell coupled to a door module. The door shell includes an outer panel secured to an inner panel, the inner panel having an opening therein. The door shell defines a hollow cavity. The door module includes a cassette and an interior trim panel coupled to the cassette. The door module further includes an attachment mechanism for securing the door module to the door shell. The attachment mechanism is visually hidden during operation of the door. The inner panel is cooperative with the door module to provide a positive rest position for the door module prior to securing the door module to the door shell.

Abstract: A clamp assembly for mounting a tonneau cover on a motor vehicle having a cargo area defined by first and second side walls, an end wall and a tailgate, the side walls having an inner panel and an outer panel includes a fastener, a first coupler plate and a bracket. The first coupler plate has a first end and a second end. The first coupler plate is articulable from an operable position to a disengaged position. The bracket has a generally horizontal rail and a vertical rail. The bracket is adapted for contacting the outer panel of the first side wall and further has a seat pivotally retaining the first end of the first coupler plate. The second end of the first coupler plate is adapted for engaging the inner panel of the first side wall defining a first restraining area between the horizontal rail and the second end of the first coupler plate. A second restraining area between the vertical rail and the second end of the first coupler plate is also defined.

Abstract: A closure member for a closing an aperture in a vehicle body. The closure member includes a frame structure and a seal member. The frame structure has an upper frame member that defines a window aperture. The seal member is formed onto at least a portion of the frame member and includes a body seal portion and a window seal portion. The body seal portion forms a seal between the vehicle body and at least a portion of the upper frame member. The window seal portion forms a seal between the at least a portion of the upper frame member and a window member that is movable relative to the frame structure. A method for forming a closure member is also provided.

Abstract: A door assembly for a vehicle. The door assembly includes a frame structure and an intrusion structure. The frame structure includes an inner panel member and an outer panel member. The intrusion structure has an impact absorbing portion and is coupled to the frame structure such that the intrusion structure abuts an exterior surface of the outer panel member. A method for fabricating a vehicle door assembly is also provided.

Abstract: A stake pocket tie down for a motor vehicle having a cargo area defined by a first sidewall, a second sidewall, a bed and a tailgate is disclosed. The first sidewall has a stake pocket defined by a top surface and a downwardly extending flange. The stake pocket tie down includes a cap, a first locking plate and a second locking plate. The cap has a wall with a first aperture and a second aperture and a flange radially extending from the wall. The first locking plate has male clasp and a finger disposed in the first aperture. The second locking plate has female clasp engaged with the male clasp and a finger disposed in the second aperture.

Abstract: A closure member assembly for a vehicle having a vehicle body that defines an aperture. The closure member assembly is positionable between a first position wherein the closure member assembly substantially closes the aperture and a second position wherein the closure member assembly substantially clears the aperture. The closure member assembly includes a first structure, a second structure and a drive mechanism. The first structure is movably coupled to the vehicle body. The second structure is pivotably coupled to the first structure about a generally horizontal pivot axis. The drive mechanism is coupled to one of the first and second structures and operable in an actuated condition for pivoting the second structure about the generally horizontal pivot axis.

Abstract: A transfer/injection molding apparatus and process is defined that includes a charge forming unit. The charge is formed so that the fibers therein are randomly oriented in substantially parallel horizontal planes such that they are always substantially parallel to the direction of initial flow into the cavity of the molding unit. The charge forming unit includes a cutter for cutting sheet material into strips and a wind-up fork for rolling the strips into wrapped charges. The wrapped charges are formed by winding the strips around prongs extending from the wind-up fork. Further, the fork is attached to a robotic arm which loads the wrapped charge into the molding die.

Abstract: A clamp assembly for mounting a tonneau cover on a motor vehicle having a cargo area defined by first and second side walls, an end wall and a tailgate, the side walls having an inner panel and an outer panel includes a fastener, a first coupler plate and a bracket. The first coupler plate has a first end and a second end. The first coupler plate is articulable from an operable position to a disengaged position. The bracket has a generally horizontal rail and a vertical rail. The bracket is adapted for contacting the outer panel of the first side wall and further has a seat pivotally retaining the first end of the first coupler plate. The second end of the first coupler plate is adapted for engaging the inner panel of the first side wall defining a first restraining area between the horizontal rail and the second end of the first coupler plate. A second restraining area between the vertical rail and the second end of the first coupler plate is also defined.

Abstract: A hydroformed member having internal reinforcements and method of manufacturing the same. The method includes the steps of providing a die having a tooling cavity and a pair of opposing rams disposed in the tooling cavity. A tubular member is enclosed within the tooling cavity. The pair of opposing rams are then driven against opposing sides of the tubular member to form a pair of opposing indentations therein. While the rams remain in place, hydraulic fluid pressure is then applied within the tubular member causing the walls of the tubular member to closely conform to the shape of the tooling cavity and the pair of opposing rams.