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: An acoustic barrier assembly for a vehicle and a method of manufacturing the same is disclosed. A decoupler layer surrounds a pass-through opening in a wall of the vehicle to defining a decoupler aperture that is open to the pass-through opening. A barrier layer abuts the decoupler layer and defines a barrier aperture that is also open to the pass-through opening. An acoustic seal is integrally formed in the barrier layer. The acoustic seal defines an exposed region of the barrier layer that is not bounded by the decoupler layer. The exposed region of the barrier layer directly contacts the wall around the pass-through opening and seals around a penetrating member that extends through the pass-through opening. The acoustic seal thus reduces flanking noise traveling through a gap between the penetrating member and the pass-through opening.

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: The disclosed acoustic insulator mat includes a first absorber layer made of a non-woven fibrous material. The non-woven fibrous material comprises a mesh of intertwined fibers that defines a plurality of cavities. The first absorber layer has a first side and a second side. Peripheral cavities are arranged along the second side of the first absorber layer between peripheral fibers. A coating is disposed on the second side of the first absorber layer. The coating is adhered to the peripheral fibers and thus includes a plurality of discontinuities at the peripheral cavities such that the coating provides a partial barrier to noise at the second side of the first absorber layer. The acoustic insulator mat may optionally include a second absorber layer that is retained on the first absorber layer by the coating. A method of manufacturing the acoustic insulator mat is also disclosed.

Abstract: The disclosed acoustic insulator mat includes a first absorber layer made of a non-woven fibrous material. The non-woven fibrous material comprises a mesh of intertwined fibers that defines a plurality of cavities. The first absorber layer has a first side and a second side. Peripheral cavities are arranged along the second side of the first absorber layer between peripheral fibers. A coating is disposed on the second side of the first absorber layer. The coating is adhered to the peripheral fibers and thus includes a plurality of discontinuities at the peripheral cavities such that the coating provides a partial barrier to noise at the second side of the first absorber layer. The acoustic insulator mat may optionally include a second absorber layer that is retained on the first absorber layer by the coating. A method of manufacturing the acoustic insulator mat is also disclosed.

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: A 3-layer acoustic insulator system includes an acoustic de-coupler layer, a film acoustic barrier layer connected to the de-coupler layer, and a microfiber acoustic absorber layer connected to an opposite side of the barrier film layer as the acoustic de-coupler layer. The acoustic de-coupler layer is positioned in direct contact with a vehicle component and mimics the geometry of the vehicle component. The acoustic absorber layer is positioned on a passenger compartment facing side of the vehicle component.

Abstract: A 3-layer acoustic insulator system includes an acoustic de-coupler layer, a film acoustic barrier layer connected to the de-coupler layer, and a microfiber acoustic absorber layer connected to an opposite side of the barrier film layer as the acoustic de-coupler layer. The acoustic de-coupler layer is positioned in direct contact with a vehicle component and mimics the geometry of the vehicle component. The acoustic absorber layer is positioned on a passenger compartment facing side of the vehicle component.

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 vehicle moisture barrier comprises a formed barrier film and one or more bend flaps. The bend flaps may be bent along a bend axis formed by a deformation created at a junction line between the bend flap and the barrier film. The distal or free end of the bend flap contacts a trim panel to provide a stiffening force proximate to a raised rib extending from the opposite side of the barrier to promote sealing of the raised rib when a drawn form opposite to the raised rib is not provided to promote such sealing.

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 water and acoustic barrier positionable between a vehicle trim piece and a vehicle body member includes a sheet having a first layer formed of an interpolymer material and a second sheet layer formed of a polyethylene material. A raised rib is formed about at least a portion of a sheet perimeter. The raised rib having an adhesive bead forms a seal between the sheet and the vehicle body member. A raised form positioned adjacent the raised rib but oppositely oriented from the raised rib acts to substantially equalize a sealing pressure along the length of the raised rib. A plurality of apertures define fastener attachment points to connect the barrier to the vehicle trim piece.

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.