Abstract: The invention relates to reinforced composite inner roof panels of the sandwich-type having a cellular core. In a method for making a inner roof panel of the invention, a stack is formed that is made up of: an upper skin made of a reinforced thermoplastic material; a cellular core made of a thermoplastic material; and a bottom skin made of a reinforced thermoplastic material. The upper and lower skins and the cellular core are formed together and have regions of reduced thickness and regions of increased thickness that may provide head impact absorbing characteristics or form structural components of the passenger compartment. Examples of structural components that may be formed include HVAC ducts, wiring conduits, video display panel mounts or air bag receptacles.

Abstract: A method is provided for manufacturing a painted plastic component having a badge, emblem or other ornamentation, such as air bag covers having a badge, or wherein the component is the badge itself. The method includes providing a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A method and system for bonding plastic parts together utilizing a heat-activated adhesive and at least one infrared lamp are disclosed. The system preferably includes first and second infrared lamps for emitting infrared radiation. A first base section supports a first infrared lamp adjacent the first plastic part and a second base section supports the second infrared lamp adjacent the second plastic part. The system also includes a controller coupled to the first and second infrared lamps for controlling power supplied to the first and second infrared lamps so that the first infrared lamp emits infrared radiation which propagates through the first plastic part and is absorbed by the adhesive and the second infrared lamp emits infrared radiation which propagates through the second plastic part and is absorbed by the adhesive for a time sufficient to heat the adhesive to a desired temperature at which the adhesive is activated.

Abstract: A method of applying a polymer to a glass surface includes applying atmospheric plasma to a glass surface, applying a film of polymerizable fluid to the surface and curing the film with high-energy radiation. Apparatus for applying atmospheric plasma includes positive and ground electrodes, and an emitter strip of porous material with a plasma gas diffusing between the electrodes and through the emitter strip onto the glass surface.

Abstract: The present invention comprises a conveyor assembly for carrying an item that has been painted by over-spray or dipping to a cleaning chamber where a cleaning means, typically a high pressure water cleaning device, is used to remove paint layers from an inadvertently painted item. The cleaning chamber further comprises a pool having an elongated drainage element such that water may be drained off from the top of the surface of the pool while the paint layers are deposited into the pool. The paint layers may subsequently be removed from the pool and disposed of properly. The invention further comprises a method of using the cleaning chamber, high pressure water cleaning device, pool and drainage device to clean items used to hold items to be painted.

Abstract: A method and system of manufacturing an air bag cover assembly utilizing infrared radiation is disclosed. The assembly includes a front panel, a back plate, a switch and infrared-absorbing material. Initially, the front panel and the back plate are positioned so that inner surfaces of the front panel and the back plate define a switch pocket therebetween. Then the switch is positioned in the switch pocket. Thereafter, infrared radiation is directed at the infrared-absorbing material for a time sufficient to heat the infrared-absorbing material to a desired temperature. The amount of heat applied to the infrared-absorbing material by the infrared radiation is controlled by a controller. Finally, the heated material cools to fixedly secures the back plate to the front panel. The heated material may be forced to flow prior to cooling.

Abstract: A removable hardtop including inner and outer roof panels made of molded fiber reinforced sheet molding compound. An integral roll bar is formed in the inner roof panel. A hold down clamp and bracket having horizontal, vertical and transverse flanges mounted on a horizontal edge, vertical surface and transverse surface of a B pillar of a vehicle. A method of molding the inner and outer roof panels and assembling component parts to the inner and outer roof panels is also disclosed.

Abstract: The present invention involves a carbon fiber-filled sheet molding compound and method of manufacturing the same. The invention comprises providing chopped automotive carbon fibers, a predetermined resin paste, a first carrier film, and a second carrier film. The method further involves coating substantially completely one side of one of the first and second carrier films with the predetermined resin paste to define a coated side, depositing the chopped automotive carbon fibers onto the coated side, and covering the deposited carbon fibers with the second carrier film to define a compactible carbon-filled laminate. The method further includes compacting the carbon-filled laminate to admix the resin paste with the carbon fibers between the films, whereby to form the automotive carbon fiber-filled sheet molding compound.

Abstract: A reinforced composite pallet assembly of the sandwich-type having a cellular core which is locally crushed is provided. The assembly includes a pair of substantially flat decks having front, back and side edges. Each of the decks includes a load-bearing skin made of a reinforced thermoplastics material, a grid of reinforcing slats, a cellular core made of a thermoplastics material, and a tine-engaging skin made of a reinforced thermoplastics material. The grid of reinforcing slats is positioned at predetermined places against the tine-engaging skins. The distance between the skins of each deck is reduced during molding of the deck which molding locally crushes the core at the predetermined places. A plurality of supports support the decks at the predetermined places against the reinforcing slats so that tines can lift and support the pallet assembly at the tine-engaging skin. The resulting assembly is ultra light weight, meeting all forecasted government weight restrictions.

Abstract: A method of priming a sheet molding compound (SMC) part. The method includes applying a photopolymerizable priming composition to a surface of the SMC part. The priming composition includes a polymerizable component, a photoinitiating component, and a conductive component. The method also includes irradiating the priming composition with light to initiate a polymerization reaction. The priming composition polymerizes on the SMC part substantially without releasing volatile solvents.

Abstract: Lightweight, thermoplastic, vehicle headliners each having at least one integrally-formed, energy-absorbing, head-impact mechanism and injection molding methods for making same are provided. Each headliner includes a stiff, self-supporting, thermoplastic sheet adapted to be mounted adjacent a roof of the vehicle so as to underlie the roof and shield the roof from view. The sheet has an upper surface and a lower surface. Each energy-absorbing, head-impact mechanism absorbs energy of an impact with its associated headliner by a passenger of the vehicle. In one embodiment, the at least one head-impact mechanism includes a plurality of spaced-apart, energy-absorbing, thermoplastic structures, such as ribs, which are connected to and extend upwardly from the upper surface of its thermoplastic sheet.

Abstract: A unitary composite air bag cover including a one-piece thermoplastic elastomeric body and a one-piece outer layer molded from a thermoplastic material compatible with the thermoplastic elastomer of the body is provided so that a bottom contact surface of the outer layer bonds with a front contact surface of the front panel by diffusion between the contact surfaces thereof. In a method of the present invention, the resulting air bag cover is cooled beneath the softening point of both plastics so that a molecular concentration gradient is formed at an interface between the first and second plastics to bond the first and second plastics by diffusion within a mold cavity of a mold separate from the mold cavity of another mold which is utilized to injection-mold either the elastomeric body or the outer layer.

Abstract: The present invention involves a carbon fiber-filled sheet molding compound and method of manufacturing the same. The invention comprises providing chopped automotive carbon fibers, a predetermined resin paste, a first carrier film, and a second carrier film. The method further involves coating substantially completely one side of one of the first and second carrier films with the predetermined resin paste to define a coated side, depositing the chopped automotive carbon fibers onto the coated side, and covering the deposited carbon fibers with the second carrier film to define a compactible carbon-filled laminate. The method further includes compacting the carbon-filled laminate to admix the resin paste with the carbon fibers between the films, whereby to form the automotive carbon fiber-filled sheet molding compound.

Abstract: A molding method and a metal-covered plastic component such as partial or entire fascia, body side moldings, and the like, which have bright surface requirements and which includes a film sheet and a one-piece thermoplastic elastomeric structural carrier are provided. The film sheet includes a decorative layer of metal such as chrome. A plastic layer of the film sheet on which the layer of metal is formed is selected from a group consisting of polyester, polyurethane and polycarbonate. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the step of forming a preform which is securely positioned within the injection mold during injection molding to form the plastic part.

Abstract: A method and system for molding thermoplastic sandwich material to form a deep-drawn article utilizing a unique clamping technique and mechanism are described. The method includes the steps of positioning a blank of thermoplastic sandwich material having a cellular core over a female die having an article-defining cavity defined by inner surfaces of the female die. Then, an inner portion of the blank is forced into the female die along a substantially vertical axis and against the inner surfaces of the female die to obtain deep-drawn material. During the step of forcing at least one outer portion of the blank immediately adjacent the female die is clamped to guide the at least one outer portion of the blank to travel into the article-defining cavity at an acute angle with respect to the vertical axis. Thickness of at least one side wall of the deep-drawn material is substantially the same as thickness of the blank of thermoplastic sandwich material.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A step for entering and exiting a vehicle. The step is a unitary one piece mold having at least two hollow U-shaped portions wherein each portion has a receding body section and first and second legs extending from the body section to first and second distal ends respectively. Each distal end has a flange configured to be mounted to a vehicle. The one piece mold further has a plate portion on the respective receiving body section for supporting weight placed thereon and integrally bridging and joining the at least two U-shaped portions together.

Abstract: A method and system for co-molding a thermoplastic material with a thermoplastic sandwich material to form a thermoplastic sandwich article having a thermoplastic inner portion are provided. In one embodiment, the thermoplastic material may be a composite material and the article is a deep-drawn article. In this embodiment, the method and system include a female die having an article-defining cavity defined by inner surfaces of the female die and an outer male die for forcing an inner portion of a blank of thermoplastic sandwich material having a cellular core and a predetermined amount of thermoplastic composite material placed on the blank into the female die along a substantially vertical axis and against the inner surfaces of the female die to obtain deep-drawn sandwich material. In a second embodiment in which the article formed is not deep-drawn, the outer male die is not required.

Abstract: The present invention involves a mounting fastener attachable to a panel member of a vehicle for retention of the panel member to a support structure. The mounting fastener comprises a base member having first and second opposing ends and is substantially planar for attachment to the panel member. The mounting fastener further comprises a biased member having first and second legs respectively extending from the first and second ends. The first and second legs merge together into a substantially parallel relationship at a head. The head has first and second wings respectively extending from the first and second legs toward the base member, wherein each wing has a flap which is twisted with respect to the wing and extends outwardly to a distal edge. The distal edge forms an acute angle with respect to the wing.

Abstract: Lightweight, thermoplastic, vehicle headliners each having at least one integrally-formed, energy-absorbing, head-impact mechanism and injection molding methods for making same are provided. Each headliner includes a stiff, self-supporting, thermoplastic sheet adapted to be mounted adjacent a roof of the vehicle so as to underlie the roof and shield the roof from view. The sheet has an upper surface and a lower surface. Each energy-absorbing, head-impact mechanism absorbs energy of an impact with its associated headliner by a passenger of the vehicle. In one embodiment, the at least one head-impact mechanism includes a plurality of spaced-apart, energy-absorbing, thermoplastic structures, such as ribs, which are connected to and extend upwardly from the upper surface of its thermoplastic sheet.