Abstract: A composite high density plastic sheet, comprising a thermoplastic elastomer filled in substantial amount with an inorganic material, and intimately blended with a high strength low density polyethylene whereby to provide in one product the benefits of sound attenuation as well as inhibiting water and dust entry. The sheet can be cold-formed to include a pocket portion for use in applications such as receiving vehicle apparatus. Provision of a separate layer of the low density polyethylene assists in the sheets being stacked and adhesive permits the sheet to be removably attached to a surface of the apparatus.

Abstract: A door for a motor vehicle. The door comprises an outer panel, a trim panel and a water shield. The water shield includes, a rigid substrate and a wire harness. The wire harness has a first terminal communicating with at least one actuator of the outer panel a second terminal communicating with at least one switch of the trim panel, and a connecting portion. The connection portion electrically connects the first and second terminals, and is substantially encapsulated within the substrate.

Abstract: A composite high density plastic sheet, comprising a thermoplastic elastomer filled in substantial amount with an inorganic material, and intimately blended with a high strength low density polyethylene or elastomeric polymer whereby to provide one product the benefits of sound attenuation as well as inhibiting water and dust entry. The sheet can be cold-formed to include a pocket portion for use in applications such as receiving vehicle apparatus. Provision of a separate layer of the low density polyethylene assists in the sheets being stacked and adhesive permits the sheet to be removably attached to a surface of the apparatus.

Abstract: A method of making a water shield for a motor vehicle. The method comprises providing a mold having a cavity with the general shape of the water shield and also having a movable core. A first plastic is injected into the cavity to form a substrate of the water shield. The core is withdrawn, and a second plastic is injected into the mold in proximate the first plastic to form a gasket of the water shield. The plastics are cooled to form the substrate having a first durometer and to form the gasket having a second durometer softer than the first durometer.

Abstract: An anti-theft protection device for a motor vehicle. In an exemplary application, the anti-theft protection device for a motor vehicle includes a passenger door watershield having a pass-through slit formed therein and an anti-theft sleeve located proximate thereto which encloses and protects the passenger door link rods.

Abstract: A reinforced pallet (20) and method for making the same are disclosed. The pallet (20) includes a body (28) having a pair of laterally spaced apart edge portions (56) with a central span (60) extending therebetween. A flexible tensile member (26) extends between the edge portions (56) and generally beneath the central span (60). The tensile member (26) may be in the form of a mesh affixed between upper and lower decks (22,24) of the pallet (20). When the edge portions (56) of the pallet (20) are simply supported and a load is place atop the pallet (20), the central span (60) of the pallet (20) will vertically deflect in response to the load. The central span (60) will bear upon the tensile member (26) with the tensile member providing support against deflection. A method for retrofitting a pallet (200) includes adding a tensile member (210) to the pallet (200) to reduce the amount of deflection of the pallet (200) when simply supported in response to a load placed atop the pallet (200).

Abstract: A composite high density plastic sheet, comprising a thermoplastic elastomer filled in substantial amount with an inorganic material, and intimately blended with a high strength low density polyethylene or elastomeric polymer whereby to provide one product the benefits of sound attenuation as well as inhibiting water and dust entry. The sheet can be cold-formed to include a pocket portion for use in applications such as receiving vehicle apparatus. Provision of a separate layer of the low density polyethylene assists in the sheets being stacked and adhesive permits the sheet to be removably attached to a surface of the apparatus.

Abstract: A plastic pallet has improved strength characteristics by the use of bosses arranged so as to avoid forming hinge lines in the deck. The arrangement is generally non-symmetrical about any axis of the deck. The bosses can be of varying sizes and varying depth.

Abstract: A reinforced pallet (20) and method for making the same are disclosed. The pallet (20) includes a body (28) having a pair of laterally spaced apart edge portions (56) with a central span (60) extending therebetween. A flexible tensile member (26) extends between the edge portions (56) and generally beneath the central span (60). The tensile member (26) may be in the form of a mesh affixed between upper and lower decks (22,24) of the pallet (20). When the edge portions (56) of the pallet (20) are simply supported and a load is place atop the pallet (20), the central span (60) of the pallet (20) will vertically deflect in response to the load. The central span (60) will bear upon the tensile member (26) with the tensile member providing support against deflection. A method for retrofitting a pallet (200) includes adding a tensile member (210) to the pallet (200) to reduce the amount of deflection of the pallet (200) when simply supported in response to a load placed atop the pallet (200).

Abstract: An apparatus is disclosed for distributing a load applied thereto, such as by a shipping pallet. The apparatus comprises first and second thermoformed plastic sheets. The first sheet has a generally planar surface, a central indentation and a plurality of symmetrical peripheral indentations disposed around the central indentation, and a plurality of first ribs extending radially from the central indentation. The second sheet is joined with the first sheet and has a series of adjacent first channels which form a generally diamond-shaped patten. Each pair of adjacent first channels is separated by a raised portion including a groove and a pair of second ribs flanking the groove. Both the first channels and the grooves of the second sheet are recessed below a plane defined by the raised portions, the grooves being recessed to a depth less than the first channels.

Abstract: An apparatus is disclosed for distributing a load applied thereto, such as by a shipping pallet. The apparatus comprises first and second thermoformed plastic sheets. The first sheet has a generally planar surface, a central indentation and a plurality of symmetrical peripheral indentations disposed around the central indentation, and a plurality of first ribs extending radially from the central indentation. The second sheet is joined with the first sheet and has a series of adjacent first channels which form a generally diamond-shaped patten. Each pair of adjacent first channels is separated by a raised portion including a groove and a pair of second ribs flanking the groove. Both the first channels and the grooves of the second sheet are recessed below a plane defined by the raised portions, the grooves being recessed to a depth less than the first channels.

Abstract: A composite high density plastic sheet, comprising a thermoplastic elastomer filled in substantial amount with an inorganic material, and intimately blended with a high strength low density polyethylene whereby to provide in one product the benefits of sound attenuation as well as inhibiting water and dust entry. The sheet can be cold-formed to include a pocket portion for use in applications such as receiving vehicle apparatus. Provision of a separate layer of the low density polyethylene assists in the sheets being stacked and adhesive permits the sheet to be removably attached to a surface of the apparatus.

Abstract: In producing a twin sheet thermoformed structure, a mold is provided with major rib producing structures segregrated into discrete tabs with gaps between tabs. A first sheet of material is fused upon itself by drawing the material into the gaps between tabs from both sides of the gap. The material drawn into the gaps fuses upon contact with material being drawn into the gap from the other side forming a cross rib which tends to stabilize the side walls of the major rib. The first sheet is then fused to a second sheet of material to create a twin sheet structure.

Abstract: A multi-layer laminated trim panel having a first sheet of high density cross-linked polyethylene foam, a second sheet of low density cross-linked polyethylene foam, a plurality of fasteners wherein the fastener heads are entrapped between the first and second sheets of cross-linked polyethylene foam, and an external cover sheet of cloth or vinyl. Additional sheets or pieces of cross-linked polyethylene foam can be incorporated between the first and second sheets of cross-linked polyethylene foam. Various methods of manufacturing the trim panels of the present invention are also disclosed.

Abstract: A multi-layer laminated trim panel having a first sheet of high density cross-linked polyethylene foam, a second sheet of low density cross-linked polyethylene foam, a plurality of fasteners wherein the fastener heads are entrapped between the first and second sheets of cross-linked polyethylene foam, and an external cover sheet of cloth or vinyl. Additional sheets or pieces of cross-linked polyethylene foam can be incorporated between the first and second sheets of cross-linked polyethylene foam. Various methods of manufacturing the trim panels of the present invention are also disclosed.

Abstract: A cover of generally rectangular shape having a deformation reinforced central section comprises thermoforming top and bottom sheets of thermoplastic to form a specially configured arrangement of strengthening ribs which extend in longitudinal and oblique directions and of a post and receptacle centrally of the sheets, and pressing the sheets together to form a closed interior. The longitudinal ribs on the bottom sheet intersect and are welded to the oblique ribs or the top sheet respective and the post is welded into the receptacle to reinforce the center of the cover. The sheet edges are welded together to reinforce the cover shape and form a reinforced hinge support.

Abstract: A simulated fabric is produced by heating a substrate having a layer of flocked material so that both the substrate and the flocked material are softened, and applying the surface of a mold, having a finely detailed simulated fabric pattern on it, to the flocked material to plastically deform the flock to a thickness less than the original thickness such that it acquires substantially the same pattern as on the mold surface.

Abstract: Disclosed is a roll cradle pallet having an arcuate support portion to support an object. Also disclosed is a method for fabricating a roll cradle pallet.