Abstract: A method of manufacturing a printed, laminated pickup truck bed and bed liner includes the steps of forming by extrusion or another process a single or double layer substrate of a desired thickness and strength. If a single layer, it will preferably be formed of a thermoplastic material such as high density polyethylene (HDPE). If a double layer, the lower layer may be HDPE or HDPE reinforced with random fibers or a fibrous material to improve its strength and ruggedness. Additionally, a cast or blow film upon which may be printed a desired pattern such as, for example, camouflage or indicia, is utilized as the top layer of the material. The two or three layers are laminated together either with or without the use of an adhesive and then formed into a bed or bed liner by a thermoforming process.

Abstract: Described herein is a process for manufacturing a part or a part pre-form, for example, a vehicle part or vehicle part pre-form, as well as articles of manufacture incorporating pre-stretched paint films and substrates such as extruded sheet. Also described herein is an apparatus useful for the process described, which process includes providing a paint film having a length as measured along a longitudinal axis of the paint film; continuously stretching the paint film in the transverse and/or longitudinal directions of the film over the length of the paint film to form a pre-stretched paint film; and applying the pre-stretched paint film to a thermoformable substrate to form a part or part pre-form.

Abstract: A running board for a passenger car or light truck is assembled from an upper molded thermoplastic section or component having a Class A automotive finish and a lower component or section having reinforcing ribs and mounting brackets. The upper section includes three layers: a paint film having a Class A automotive finish, a thin layer of thermoplastic polyolefin (TPO) and a thick layer of polypropylene. The lower section is homogeneous and may be a plastic such as TPO, polypropylene or high-density polyethylene (HDPE), for example, which may contain chopped, randomly oriented glass reinforcing fibers. The two sections are secured to one another about their peripheries by autogenous bonding.

Abstract: A method of fabricating composite vehicle panels includes the steps of forming a first, upper panel having a depending peripheral lip, forming a second, lower panel of laid up woven mat or strips of a fibrous material such as fiberglass or carbon fibers and a plastic resin to form a corrugated panel having a depending peripheral lip, placing an adhesive on the raised portions of the corrugations and the peripheral lip of the second panel and securing the panels together at the corrugations and about their peripheral lips.

Abstract: Clip for attaching a bed liner to a cargo area of a vehicle such as a pickup truck can include a body to which is attached an ear, and attached to the ear, a toe that can engage a vertical portion of a wall of the bed liner; optionally, a hole may be provided in the body to disengage the toe from the bed liner wall opposite the toe. The clip in another embodiment can include a body to which is attached a biasing upper extension arm, and a laterally directed retaining member, and between the body and the laterally directed retaining member is provided at least one gap for receiving a wall portion of the bed liner; optionally, a recess may be provided to accommodate a blind lip tab of the pickup truck cargo area wall.

Abstract: A method of fabricating composite vehicle panels includes the steps of forming a first, upper panel having a depending peripheral lip, forming a second, lower panel of laid up woven mat or strips of a fibrous material such as fiberglass or carbon fibers and a plastic resin to form a corrugated panel having a depending peripheral lip, placing an adhesive on the raised portions of the corrugations and the peripheral lip of the second panel and securing the panels together at the corrugations and about their peripheral lips.

Abstract: Described herein is a process for manufacturing a part or a part pre-form, for example, a vehicle part or vehicle part pre-form, as well as articles of manufacture incorporating pre-stretched paint films and substrates such as extruded sheet. Also described herein is an apparatus useful for the process described, which process includes providing a paint film having a length as measured along a longitudinal axis of the paint film; continuously stretching the paint film in the transverse and/or longitudinal directions of the film over the length of the paint film to form a pre-stretched paint film; and applying the pre-stretched paint film to a thermoformable substrate to form a part or part pre-form.

Abstract: A method of fabricating composite vehicle panels includes the steps of forming a first, upper panel having a depending peripheral lip, forming a second, lower panel of laid up woven mat or strips of a fibrous material such as fiberglass or carbon fibers and a plastic resin to form a corrugated panel having a depending peripheral lip, placing an adhesive on the raised portions of the corrugations and the peripheral lip of the second panel and securing the panels together at the corrugations and about their peripheral lips.

Abstract: A method of manufacturing a laminated pickup truck bed and bed liner includes the steps of forming by extrusion or another process a substrate layer of a desired thickness and strength of a thermoplastic material such as high-density polyethylene (HDPE) which may include fibers or a fibrous mat which improves its strength and ruggedness. Also formed by extrusion or another process is an upper layer having specific characteristics such as electrical charge dissipation or improved skid or slip resistance. The upper layer may be fabricated of a thermoplastic material such as HDPE and includes dispersed conductive material such as carbon particles, carbon, fibers or conductive polymers which dissipate or carry static electrical charges to a vehicle ground. Skid or slip resistance may be achieved by controlling the upper layer surface texture or the use of various materials and mixtures.

Abstract: A motor vehicle bed or bed liner is vacuum formed from a single layer or two layer panel of thermoplastic material having a scuffed or roughened surface. The single layer panel is typically extruded and is homogeneous, being either a single material such as HDPE or a uniform mixture of materials. The two layer panel is co-formed of two layers of material which will typically be distinct compositions and characteristics. The upper surface of the panel is scuffed or roughened by a brush which contacts the surface. A bank of individually adjustable rollers supports the panel during the roughening operation and facilitates adjustment of the extent of contact or impingement of the brush on the surface of the panel at a plurality of transverse locations across the panel. The roughened panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

Abstract: A motor vehicle bed or bed liner is vacuum formed from a single layer or two layer panel of thermoplastic material having a scuffed or roughened surface. The single layer panel is typically extruded and is homogeneous, being either a single material such as HDPE or a uniform mixture of materials. The two layer panel is co-formed of two layers of material which will typically be distinct compositions and characteristics. The upper surface of the panel is scuffed or roughened by a brush which contacts the surface. A bank of individually adjustable rollers supports the panel during the roughening operation and facilitates adjustment of the extent of contact or impingement of the brush on the surface of the panel at a plurality of transverse locations across the panel. The roughened panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

Abstract: A motor vehicle bed or bed liner is vacuum formed from a panel of co-formed layers of thermoplastic material having a roughened surface. The panel is co-formed of two layers of material having distinct compositions and characteristics. The upper surface of the co-formed composite is then roughened or textured by a brush which contacts one surface. The co-formed and roughened composite panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

Abstract: A method of forming thermoplastic panels is disclosed which includes the steps of forming the thermoplastic panels by extrusion or a similar process and simultaneously or subsequently texturing or graining at least one face thereof, and utilizing such pre-textured or pre-grained panels to form a finished panel or article by disposing such panel in a thermoforming mold having at least one grained or textured mold surface against which the pre-textured or pre-grained surface of the panel is disposed and thermoforming such panel. The process provides a textured or grained surface having greatly improved uniformity and enhanced appearance.

Abstract: A motor vehicle bed or bed liner is vacuum formed from a single layer or two layer panel of thermoplastic material having a scuffed or roughened surface. The single layer panel is typically extruded and is homogeneous, being either a single material such as HDPE or a uniform mixture of materials. The two layer panel is co-formed of two layers of material which will typically be distinct compositions and characteristics. The upper surface of the panel is scuffed or roughened by a brush which contacts the surface. A bank of individually adjustable rollers supports the panel during the roughening operation and facilitates adjustment of the extent of contact or impingement of the brush on the surface of the panel at a plurality of transverse locations across the panel. The roughened panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

Abstract: A truck bed or liner for installation in a pickup truck bed or cargo vehicle exhibits improved electrical charge dissipating characteristics. The preferred embodiment bed is manufactured of high density polyethylene (HDPE) or similar material containing particles of conductive material such as carbon black dispersed therethrough. In a first alternate embodiment, the bed defines a two-layer composite or sandwich. The upper layer of HDPE or similar material includes dispersed carbon black particles whereas the lower layer is free of such particles. A second alternate embodiment of the invention comprehends a bed liner for disposition in a pickup truck or the like wherein the conductive material is dispersed throughout the liner material. In a third alternate embodiment, the bed liner of the second alternate embodiment is combined with the composite conductive and non-conductive layers of the first alternate embodiment.

Abstract: A six station rotary thermoforming machine includes a first oading station for first or upper panels, a second loading station for second or lower panels, two adjacent stations for heating the panels, a thermoforming station, an unloading station and a carousel for transferring thermoformable panels between such stations. The carousel includes a rotating circular frame which is driven by a centrally disposed drive assembly. The circular frame carries and supports six carrier assemblies having peripheral clamping members which receive panels of thermoformable material and rotates to sequentially move them from one station to the next. The two heating stations each include upper and lower radiant heaters. The thermoforming station includes a pair of opposed, vertically translatable platens which receive respective molds which engage and form the panels and may include a device for loading performs or inserts.

Abstract: A truck bed or liner for installation in a pickup truck bed or cargo vehicle exhibits improved electrical charge dissipating characteristics. The preferred embodiment bed is manufactured of high density polyethylene (HDPE) or similar material containing particles of conductive material such as carbon black dispersed therethrough. In a first alternate embodiment, the bed defines a two-layer composite or sandwich. The upper layer of HDPE or similar material includes dispersed carbon black particles whereas the lower layer is free of such particles. A second alternate embodiment of the invention comprehends a bed liner for disposition in a pickup truck or the like wherein the conductive material is dispersed throughout the liner material. In a third alternate embodiment, the bed liner of the second alternate embodiment is combined with the composite conductive and non-conductive layers of the first alternate embodiment.

Abstract: A composite material includes five distinct layers of material: two thin outer layers or panels, a central rigid core and intermediate foam layers on both sides of the core which fill the regions between the core and outer panels. The core can be a wide variety of material but is preferably a rigid foam or wood having resin or epoxy impregnated fiber or fiber filled outer skins. An array of apertures extends through the core. During the fabrication process, the apertures facilitate cross flow of the foam and ensure even distribution thereof. As a finished product, the foam filled apertures ensure positive location and retention of the core within the foam. The foam may be any suitable injectable foam but is preferably a composition which remains resilient upon curing as such foam more readily accommodates dimensional changes between the layers due to, for example, ambient temperatures changes.

Abstract: A cargo van bulkhead provides a barrier between the driver and passenger of a van and the cargo compartment. The bulkhead comprises a molded, complexly curved unitary panel which fits snugly against the bottom, sidewalls and top of the van behind the driver's and passenger's seats. The bulkhead includes a plurality of horizontal convolutions which define alternate ribs or projections and recesses which greatly improve the rigidity and strength of the bulkhead. An irregular flange disposed about the periphery of the bulkhead is configured to mimic the interior profile of the van and thus facilitate installation and securement thereto. An optional opening in the upper central portion of the bulkhead may receive a window which facilitates inspection of the cargo within the van as well as a view out the rear of the van if the rear doors of the van are equipped with windows.