Abstract: A transfer/injection molding apparatus is defined that includes a charge forming unit, a molding unit and a charge overflow 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. Excess charge from the cavity is forced into the charge overflow unit, which is selectively located in an area where surface finish is less critical. The excess charge displaces an overflow pin, which is kept upwardly biased, under molding pressure, to be flush with the lower inside wall of the molding unit cavity.

Abstract: An automated transfer/injection molding apparatus and process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.

Abstract: In accordance with the teachings of the present invention, a vehicle door including fiber reinforced plastic (FRP) members is provided. The vehicle door includes a fiber reinforced plastic outer skin member which is adhesively bonded to a fiber reinforced plastic intermediate shell including lateral side walls cooperating with inner and outer faces to define an open box-like structure with a hollow, interior cavity. The adhesively bonded outer skin member and intermediate shell define a door subassembly to which a hinge mechanism is coupled for securement to a body of a partially assembled vehicle. The door subassembly and the body of the partially assembled vehicle are simultaneously painted during the on-line assembly process.

Abstract: An automated transfer/injection process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.

Abstract: A hybrid vehicle assembly, and more particularly, a hybrid truck assembly including a hybrid passenger cab shell and a hybrid truck box are disclosed. The hybrid passenger cab shell includes a first plurality panels which are assembled together to form an inner cab shell and a second plurality of panels which are assembled together to form an outer cab shell. Generally, at least one of the first or second pluralities of panels are formed from a plastic material such as a sheet molded compound (SMC). Similarly, the truck box portion of the vehicle is formed from a plurality of inner panels which are formed from a plastic material such as SMC and are assembled together along overlapping edge portions. Thereafter, a plurality of outer panels are attached to the respective inner panels.

Abstract: The present invention relates to a hybrid frame rail including a pair of metallic flanges separated by a composite web including a first and second sections, each section including a pair of elongated bands separated by a transversely extending wall which includes a plurality of protrusions integrally connected to complimentary protrusions provided on the complimentary web section. To manufacture the hybrid frame rail, the metallic flanges are attached over the elongated bands of the web such that the web is entrapped between the metallic flanges.

Abstract: The present invention relates to a hybrid frame rail including a pair of metallic flanges separated by a convoluted web including a plurality of alternately opposing recesses extending transversely to the flanges. In manufacture, the convoluted web is generally adhesively bonded to the flanges to form the hybrid frame rail.

Abstract: A vehicle door assembly including a tailored steel inner panel and an panel spaced apart by a belt-line reinforcement member. The tailored steel inner panel includes an intrusion beam which bridges first end and second ends of the inner panel.

Abstract: Surface imperfections on painted fiber reinforced plastic (FRP) automotive body panels are substantially eliminated by incorporating thermally conductive material into the part that serves to minimize temperature differentials on the surface of the part to be painted.

Abstract: A load-bearing structural member comprising an upper plate member, a lower plate member spaced a distance X from the upper plate member, and a reinforcing web comprising a plurality of web segments extending back and forth between the web segments in zigzag fashion, the web segments meeting the plate members at a web angle .theta., wherein the magnitude of the two variables X and .theta. are varied over the length of the structural member in accordance with the weight, strength, and shape requirements of particular sections thereof.