Abstract: A thermoformed product formed during a thermoforming process includes a thermoformed sheet of polymeric material having front and rear surfaces defining a thickness, and having a first section thermoformed to include a non-planar three-dimensional useful structure and at least one second section. Each of the at least one second sections have a first area of reduced thickness and have a second area including attachment structure, with the attachment structure being formed in part by material extruded from the first area into the attachment structure while the polymeric material of the sheet is hot during the thermoforming process.

Abstract: A thermoforming process capable of coining and flowing material is provided, such as for making a thermoformed energy absorber for self-attachment to a vehicle bumper beam. The energy absorber includes a thermoplastic sheet with first thickness shaped by a thermoforming process to include a base and lobes configured to absorb energy. The sheet further has integrally formed attachments with solid heads formed from material flowed from adjacent areas into the attachment during the thermoforming process. Many other structures can be formed, such as ringed ridges, thinned regions, snap-attachments, hooks, living hinges, bosses, and the like. The present invention further includes an apparatus and a method for accomplishing the above, such as a heater for heating the sheet, and a die for stretching and shaping the sheet, where heated material is flowed by opposing coining die components to form selectively-shaped 3D structures.

Abstract: An energy absorber includes a base sheet and a plurality of crush lobes extending from the base sheet. Each crush lobe includes a side wall oriented to crush and collapse to absorb energy when impacted in a first direction and includes an end wall. At least one of the base sheet and the end wall of at least one crush lobe includes an integrally-formed protruding countermeasure of lower standing strength than the crush lobes so that the protruding countermeasure acts to dampen movement causing buzzes, squeaks and/or rattles between the end wall and an adjacent structure. The countermeasure can be integrally formed or an insert, such as a magnet or other insert. Methods related to the above are also described.

Abstract: A thermoformed product formed during a thermoforming process includes a thermoformed sheet of polymeric material having front and rear surfaces defining a thickness, and having a first section thermoformed to include a non-planar three-dimensional useful structure and at least one second section. Each of the at least one second sections have a first area of reduced thickness and have a second area including attachment structure, with the attachment structure being formed in part by material extruded from the first area into the attachment structure while the polymeric material of the sheet is hot during the thermoforming process.

Abstract: A thermoforming process capable of coining and flowing material is provided, such as for making a thermoformed energy absorber for self-attachment to a vehicle bumper beam. The energy absorber includes a thermoplastic sheet with first thickness shaped by a thermoforming process to include a base and lobes configured to absorb energy. The sheet further has integrally formed attachments with solid heads formed from material flowed from adjacent areas into the attachment during the thermoforming process. Many other structures can be formed, such as ringed ridges, thinned regions, snap-attachments, hooks, living hinges, bosses, and the like. The present invention further includes an apparatus and a method for accomplishing the above, such as a heater for heating the sheet, and a die for stretching and shaping the sheet, where heated material is flowed by opposing coining die components to form selectively-shaped 3D structures.

Abstract: A system and method for transforming a physical representation of a functional logic system or sub-system to a logical representation of the same functional logic system or sub-system. One embodiment provides a method comprising loading a physical hardware description language (HDL) representation of the system or creating a physical HDL representation from a physical schematic of the system, identifying the power nets and component blocks, identifying initial conditions on the power nets and component blocks, converting connector blocks to hierarchical IO logical HDL representations, converting appropriate component blocks to logical HDL representations, deleting component blocks appropriate for deletion, and converting resistor components to logical HDL representations.

Abstract: A frameless pierced metal speaker grille is directly attached to a panel in which a speaker opening is formed by a series of tabs integrally formed in the speaker grille at spaced locations about the perimeter of the grille. Each tab includes a rear facing planar section extending inwardly from a turned edge perimeter of the cover grille and abutted against the panel structure, a v shaped engagement section extending rearwardly from the planar section and having legs adapted to squeeze fit the panel edge adjacent the speaker opening, and an entry section extending rearwardly from the v section and inclined inwardly to cam the tab inwardly at assembly of the grille. The tab shape enables secure spring fitting to the panel structure while being formed of the relatively mild material of the grille material which is pierced as by being perforated to form the open area cover grille.

Abstract: A method of providing interchangeability of aircraft wings, particularly providing a method of adjusting the angles of incidence and dihedral to compensate for differences in the twist angle between airfoils. The method comprises determining the angle of twist of an airfoil, having an airfoil attachment member, and supporting the airfoil on at least three supports spaced about said airfoil so that the airfoil attachment member is aligned with a hole boring means. The supports are adjusted so that the hole when bored through the airfoil attachment member provides the airfoil with angles of incidence and dihedral that substantially cancel the angle of twist. The hole is bored through the airfoil attachment member.