Abstract: Method and apparatus are disclosed wherein a required threaded hole is formed in a hydroformed part with a single tool while the part remains in a hydroforming die cavity. In forming the threaded hole, a hole is first pierced in the wall of the part and then an annular region of the part extending about the hole is extruded inwardly to form an integral tubular neck defining a hole of predetermined depth. The hole is then expanded in a sizing operation to a diameter determined by the required thread to be formed therein by material displacement and the required thread is then formed in the wall of the hole in a material displacing manner.

Abstract: Hydroforming apparatus is provided with retractable part locators that are adapted when extended to receive and hold end portions of a tubular part to be hydroformed and thereby support and hold the part between the hydroforming dies when the dies are open. Seal units mounted on separate elevators have a retractable seal carrier and the seal carriers are adapted when the seal units are elevated to advance and initially engage the respective tubular part end portions while the part is being so held. The part locators are adapted to release the end portions of the part and retract out of the way of the seal carriers to permit the seal carriers to then further advance on the respective end potions of the part to a position closely adjacent the end faces of the dies while also centering the part lengthwise with respective to the dies prior to die closure.

Abstract: Hydroforming apparatus includes in-die hydropiercing apparatus with easy and precise adjustment of the positioning of a backup plunger that is received in a die button and is positioned in a hydroforming position, a prepiercing position, a piercing position, and a slug ejecting position that may be outside the plunger or may be the hydroforming position. Wherein the plunger is required to be precisely positioned and held in the prepiercing position in the die button in order to obtain a desired prepiercing action without prematurely piercing the hydroformed part. The in-die hydropiercing apparatus has a plunger actuating hydraulic cylinder that moves the plunger to the different positions and a cam actuating hydraulic cylinder that positions a cam in determining the prepiercing position of the plunger.

Abstract: A punch for piercing and sealing hydroforming parts has a roll forming surface that produces an internal rolled edge portion in a formed part immediately following the punch piercing the part wherein the rolled edge portion acts to effect a tight high pressure seal between the part and the punch as the punch continues to form a required hole in the part. The roll-forming surface extends either partially or completely about the punch in determining the extent of the rolled edge portion in the part that it produces and is located between an end portion that effects the piercing operation and a larger finishing portion that completes the formation of the required hole.

Abstract: The seal units that form part of a hydroforming apparatus that further includes dies for hydroforming parts are each provided with a tubular part locator for locating and clamping a tubular part in alignment with the seal unit. The part locator basically comprises a locator member, a pair of pivot arms and a backup member wherein the locator member and the pivot arms together with the seal unit are supported by an elevator that aligns the seal unit and the locator member with the hydroforming dies when the latter close on the tubular part. The locator member has a concave surface and guide surfaces wherein the concave surface has a shape conforming to the outer surface of the part and the guide surfaces are adapted to guide an end portion of the tubular part onto the concave surface of the locator member and thereby into alignment with the seal unit.

Abstract: A pair of self-aligning non-pinching hydroforming dies have fingers and slots which are operable during closure of the dies on a tubular part to effect precise alignment of the dies as they are pressed together to form a hydroforming cavity about the part so that the part is not pinched between mating surfaces of the dies during their closure on the part. The fingers are further capable of mechanically straightening and/or bending the part, if need be, to prevent pinching of the part during die closure. The fingers are also capable of mechanically forming a round tubular part to a non-round cross-section region of the die cavity as the dies close to help form the part as well as prevent pinching of this section. With all such mechanical forming operations by the action of the fingers on the part performed prior to the hydroforming of the part in the die cavity.

Abstract: Method and apparatus are disclosed wherein seal units sealingly connect a hydroforming fluid pressure source with the ends of a part to be hydroformed while the part is outside an intended die cavity and wherein the seal units are then conditioned with a relatively low sealing pressure capacity. The part is prefilled through the seal units with hydroforming fluid at a relatively low pressure sufficient to prevent later pinching, buckling, splitting and cracking of the part in the die cavity during hydroforming. The prefilled part, with the seal units remaining sealingly connected, is then enclosed in the die cavity and the seal units are conditioned with a relatively high pressure sealing capacity sufficient for the continued supply of hydroforming fluid to the part through the seal units at the considerably higher pressures required for hydroforming the part.

Abstract: Hydroforming method and apparatus are disclosed for preventing or minimizing thinning of a tubular part during its hydroforming in a die cavity. Seal units are employed which each have a docking rod that sealing docks at one end with the tubular part and is counterbalanced or overpowered at an opposite end with the same hydroforming pressure that acts in the tubular part on the docking end so that a hydraulic piston that operates the docking rod need only develop sufficient force to exceed the yield strength of the tubular part to effect its compression between the docking rods and thereby effect the addition of material in the tubular part to the portions of the tubular part being stretched during hydroforming.

Abstract: A die button flush mounted in the cavity surface of a lower one of two hydroforming dies has a backup plunger received therein that forms a part of this surface when the plunger is in a hydroforming position. A slug ejector received in the lower die also forms a part of this surface and with a tubular part enclosed in the cavity formed by the dies, hydroforming fluid under pressure is supplied to the interior of the part and also to separately act on the plunger. The fluid pressure moves and holds the plunger in its hydroforming position while forming the part to the die cavity surface. The fluid pressure on the plunger is then exhausted allowing the fluid pressure in the part to stretch a portion of the part into the die button while also forcing the plunger to a position that limits this stretching to prevent piercing.

Abstract: A method of making a thermoplastic skin comprises the steps of providing a mold having a mold surface with first and second mold surface portions which intersect at a sharp corner coincident with the desired location of the tear seam in the molded skin. The mold is oriented with one of the first and second mold surface portions oriented in a generally horizontally orientation and the other of the mold surface portions oriented in a generally vertical orientation. A thermoplastic material such as polyurethane is sprayed onto the mold surface and the curing of the sprayed material is controlled to permit gravity to induce flow of the sprayed material down the vertical surface of the mold at the sharp corner and thereby provide a cured skin which is of significantly lessened thickness at the corner than at other regions of the skin.

Abstract: Method and apparatus for forming unobstructed holes in a hydroformed metal part employs a punch having a peripheral side conforming to the desired hole shape and an end face having a central cutting edge with a high point that contacts on closure of a hydroforming die with an unsupported wall section of the part initiating a stress riser therein. During forming of the part, the hydraulic pressure forces the above wall section outward against this high point increasing the magnitude of the stress riser. The punch is advanced while maintaining the hydraulic pressure causing the above high point to fracture this wall section at the stress riser and the above cutting edge to then split and cut this wall section to form oppositely facing cut edges in this section. Simultaneously, oppositely angled cutting edges at opposite ends of the central cutting edge and at the punch end face periphery then cut this wall section in directions away from the oppositely facing cut edges to form oppositely extending slugs.

Abstract: Forming apparatus includes a binder with novel flow lock beads that engage edge portions of a sheet metal blank during metal drawing. In an initial step, the beads draw inner portions of the edge portions into a die cavity to partially form a component. In a second step, the beads are inserted into bead recesses in an opposing die, locking the edge portions in place and causing stretching of the metal in a final portion of the drawing stroke. Stresses in the resulting component are relieved by the stretching process which may be selectively used in forming a component with varying draw depths across its length.

Abstract: A motor vehicle trim panel assembly and method including a molded plastic trim panel having a facia portion, an integral skirt portion, a plurality of flat cantilever platforms on an inside surface of the facia portion, and a plurality of pairs of raised bosses on the inside surface of the facia portion. Each platform has a pair of side panels attached thereto by integral “living” hinges. A push-in fastener is supported in a slot in each platform. The side panels are folded down and snapped behind the raised bosses which retain the side panels in active positions defining struts between the platform and the inside surface of the facia portion. Force applied to an outside surface of the facia portion thrusts the push-in fastener into a socket in a vehicle body panel to secure the facia portion without the push-in fasteners being externally visible. The struts react to the facia portion a fraction of the thrust applied to the push-in fastener to prevent flexure of the platform.

Abstract: A vehicle closure has a compartment latch and a handle for operating the compartment latch. The compartment latch includes a reset member that is automatically engaged to disable the compartment latch when the compartment latch is unlatched. The reset member must be reset manually to restore normal operation of the compartment latch. Manual resetting is difficult to avoid inadvertent operation by children.

Abstract: A bifold door assembly includes two foldable door panels disposed in edge adjacent relation in a door closed position and including vertically spaced hinges connected adjacent center edges of the two panels and allowing folding motion of the panels between a longitudinally aligned closed position and alternative forward and rear pivoted side by side laterally extending open positions. Each of the door panels has an upper hinge member adjacent an outer edge of the respective panel and pivotable on carrier movable along a longitudinal upper track from a first position near one end of the track to a second position spaced inward from an opposite end of the track. At least one of the door panels also has a lower hinge member adjacent an outer edge of the respective panel and pivotably connected with carrier movable along a longitudinal lower track from a first position near one end of the track to a second position spaced longitudinally from said one end of the track.

Abstract: A foldable motor vehicle seat including a horizontal seat cushion and a vertical seat back joined at a horizontal hinge for pivotal movement of the seat cushion from a horizontal position to a vertical position folded against the seat back. The seat back is connected to a side wall of a body of the motor vehicle for pivotal movement about a vertical axis between a seating position in a plane perpendicular to a longitudinal centerline of the motor vehicle and a cargo position in a plane parallel to the longitudinal centerline. With the seat cushion folded vertically against the seat back and the seat back in its cargo position, the floor of the motor vehicle under the seat is exposed for cargo. With the seat cushion horizontal and the seat back in its seating position, a passenger may sit on the foldable seat.

Abstract: A cowl panel for an automotive vehicle has a plurality of air vents which direct outside air into an air plenum for distribution to the interior of the vehicle through the heating, air conditioning and ventilation system. An air permeable mat is bonded to the underside of the cowl to cover the air vents. The mat permits the passage of air but restricts the passage of liquids such as water thereby reducing the volume of water that must be drained from the plenum.

Abstract: A motor vehicle body including a plurality of vertical pillars defining therebetween a plurality of door frames for access to a passenger compartment of the vehicle body, a plurality of doors supported by pairs of hinges on the front vertical pillar of each door frame for pivotal movement between closed and open positions, and a light weight side impact protection barrier characterized by high elongational stiffness and high strain-at-failure. The light weight barrier may be employed alone or in combination with a horizontal door beam and includes a synthetic cable in the door made from a plurality of helically braided bundles of fibers selected from a group of fibers consisting of aramid fibers and liquid crystal polymer fibers characterized by a strain-at-failure exceeding about 3%. The synthetic cable includes attachments to the front and rear pillars of the door frame when the door is closed.

Abstract: To hold the edges of a sheet metal blank during stamping or forming, such as stretch forming, a flange of the blank is clamped between faces of one of the dies and a binder which form a lockbead in the flange that restrains movement of the flange during the subsequent forming operation. A double V lockbead having three alternately angled sharp bends of near 90 degrees and one or two connecting bends totaling near 90 degrees provides improved locking performance, especially where the clamping surfaces of the die are sloped from horizontal. The legs or sides of the beads may have unequal lengths. The bend angles may be varied, in appropriate cases, within a reasonable range of from 75 to 120 degrees more or less as desired. Also, an additional angle or two, forming a third V could be used. The lockbead forming shapes are machined into the mating die and binder to form and retain the lockbead during the metal forming process.

Abstract: A selective all wheel drive powertrain has an engine and transaxle adapted to normally drive the front wheels of a vehicle. A transfer gear set, drive shaft, clutch and differential are connectable between the output of transaxle and the rear wheels of the vehicle to selectively provide an all wheel drive system. A pump, which supplies the fluid pressure to engage the clutch, has a pair of relatively rotatable members that are connected to rotate in unison with opposite sides of the clutch such that when the valve is operated, the clutch will be engaged. A selectively operable valve is disposed between a reservoir and the pump and controlled in actuation by the vehicle traction control system (TCS) to connect the pump to the reservoir when a loss of traction is sensed by the TCS. The clutch is effectively controlled by the selectively operable valve that supplies the fluid to the pump.