Abstract: A fibrous vehicle underbody shield and method for manufacturing the same is provided. A binderless core of non-woven fibrous material defines first and second surfaces of the fibrous vehicle underbody shield. The second surface of the fibrous vehicle underbody is opposite the first surface such that the first and second surfaces are separated by a final product thickness. The first and second surfaces include at least one molded contour that gives the first and second surfaces a non-planar shape. The non-woven fibrous material of the binderless core includes a plurality of fibers that are mechanically entangled with each other and have a coating that withstands a heat exposure of 200 degrees Celsius. The fibrous vehicle underbody shield includes a latex impregnation. The latex impregnation is disposed on at least one of the first and second surfaces and penetrates the non-woven fibrous material of the binderless core an impregnation distance.

Abstract: A fibrous vehicle underbody shield and method for manufacturing the same is provided. A binderless core of non-woven fibrous material defines first and second surfaces of the fibrous vehicle underbody shield. The second surface of the fibrous vehicle underbody is opposite the first surface such that the first and second surfaces are separated by a final product thickness. The first and second surfaces include at least one molded contour that gives the first and second surfaces a non-planar shape. The non-woven fibrous material of the binderless core includes a plurality of fibers that are mechanically entangled with each other and have a coating that withstands a heat exposure of 200 degrees Celsius. The fibrous vehicle underbody shield includes a latex impregnation. The latex impregnation is disposed on at least one of the first and second surfaces and penetrates the non-woven fibrous material of the binderless core an impregnation distance.

Abstract: A removable brake cover apparatus is disclosed including a sidewall presenting frontal and posterior surfaces and a circumferential wall extending transversely from the sidewall to define a brake rotor receiving cavity adjacent the posterior surface of the sidewall. A brake caliper pocket having a limited circumferential extent is disposed along the sidewall and the circumferential wall to define a brake caliper receiving cavity adjacent the brake rotor receiving cavity. Engagement fingers extend radially into the brake caliper receiving cavity to engage a brake caliper received therein with an audible and/or tactile indicator defining a fully installed position of the brake cover apparatus. Locking recesses extend radially into the brake rotor receiving cavity to engage a brake dust shield received therein.

Abstract: A removable brake cover apparatus is disclosed including a sidewall presenting frontal and posterior surfaces and a circumferential wall extending transversely from the sidewall to define a brake rotor receiving cavity adjacent the posterior surface of the sidewall. A brake caliper pocket having a limited circumferential extent is disposed along the sidewall and the circumferential wall to define a brake caliper receiving cavity adjacent the brake rotor receiving cavity. Engagement fingers extend radially into the brake caliper receiving cavity to engage a brake caliper received therein with an audible and/or tactile indicator defining a fully installed position of the brake cover apparatus. Locking recesses extend radially into the brake rotor receiving cavity to engage a brake dust shield received therein.

Abstract: An injection compression molding system includes a mold having a fixed first half and a displaceable second half. The second half is initially positioned with a cavity between the mold halves having a first clearance sized to receive a molten material puddle shot injected by an injection molding device without the puddle shot filling the cavity. A displacement device acts during or immediately after puddle shot injection, displacing the second mold half toward the first mold half creating a second clearance less than the first clearance. The second clearance defines a finished part thickness whereby displacement of the second mold half to the second clearance compresses the puddle shot so that the puddle shot fills the cavity and forms a finished part between the mold halves. Total time to inject and compress the puddle shot is less than or equal to 1.0 seconds.

Abstract: A removable wheel cover includes a dome-shaped body having a perimeter edge and a central core. A body elevation increases from the perimeter edge to a maximum elevation between the perimeter edge and the central core. Concentric raised ribs between the perimeter edge and the maximum elevation decrease in diameter between successive raised ribs toward the maximum elevation. A central core sleeve wall has an end face. An apex of each of multiple sleeve wall tabs positioned proximate the end face together define a first plane positioned with respect to a perimeter edge second plane. A wheel having a central hub is mounted to a tire. In an installed position, the perimeter edge is positioned in continuous contact with the tire or the wheel and the body is elastically deflected toward the wheel to engage the tabs against a wheel hub aperture raised edge thereby resisting wheel cover removal.

Abstract: An injection compression molding system includes a mold having a fixed first half and a displaceable second half. The second half is initially positioned with a cavity between the mold halves having a first clearance sized to receive a molten material puddle shot injected by an injection molding device without the puddle shot filling the cavity. A displacement device acts during or immediately after puddle shot injection, displacing the second mold half toward the first mold half creating a second clearance less than the first clearance. The second clearance defines a finished part thickness whereby displacement of the second mold half to the second clearance compresses the puddle shot so that the puddle shot fills the cavity and forms a finished part between the mold halves. Total time to inject and compress the puddle shot is less than or equal to 1.0 seconds.

Abstract: A removable wheel cover includes a dome-shaped body having a perimeter edge and a central core. A body elevation increases from the perimeter edge to a maximum elevation between the perimeter edge and the central core. Concentric raised ribs between the perimeter edge and the maximum elevation decrease in diameter between successive raised ribs toward the maximum elevation. A central core sleeve wall has an end face. An apex of each of multiple sleeve wall tabs positioned proximate the end face together define a first plane positioned with respect to a perimeter edge second plane. A wheel having a central hub is mounted to a tire. In an installed position, the perimeter edge is positioned in continuous contact with the tire or the wheel and the body is elastically deflected toward the wheel to engage the tabs against a wheel hub aperture raised edge thereby resisting wheel cover removal.

Abstract: A system and method for operating an injection system to create a reduced density polymeric component uses a resin/blowing agent mixture, an injection molding machine having an injection molding screw positioned in a screw section, accumulators, a hydraulic pump, multiple molds, and a cooling system. Coolant is directed into each mold. The injection molding screw is rotated moving the mixture proximate to a receiving portion of the screw section. The injection molding screw is incrementally displaced to one of a plurality of successive injection positions each injecting a portion of the mixture into one of the molds by operating the hydraulic pump and discharging the accumulators. The accumulators are recharged after each injection molding screw displacement using the hydraulic pump. The injection molding screw is displaced and the accumulators recharged for each of the successive injection positions, each defining a stage for filling the molds in a single operating cycle of the injection system.

Abstract: A method for forming energy absorbing components for motor vehicles includes mixing a polymeric resin and blowing agent combination. The combination is heated to liquefy it. A mold for receiving the liquefied combination is cooled. The liquefied combination is injected into the mold in less than 1.5 seconds and preferably in 0.5 seconds or less.

Abstract: A method for forming energy absorbing components for motor vehicles includes mixing a polymeric resin and blowing agent combination. The combination is heated, liquefied, and pressurized. A mold for receiving the liquefied combination is pre-cooled. The liquefied combination is injection molded in the mold to form the energy absorbing component.