Abstract: A method of removing material such as surface treatments, metal coatings, and other material layers from an edge region of a metal work piece where they could potentially contaminate a nearby weld. According to one embodiment, a scraper tool includes a body having a base portion and a tab portion, and several scraping elements attached to the base portion. During operation, the scraping elements scrape one or more surfaces of the edge region so that the depth to which the scraping element engage the metal work piece is generally affected by the amount of rotation of the scraper tool about a pivot axis.

Abstract: A sound-damped vehicle panel assembly, such as a dash panel, is attached to a structural member with one or more weld joints. The vehicle panel assembly may include a main panel member, a sound-damping patch, and a sound-damping adhesive layer arranged therebetween, where the patch covers at least a portion of an acoustically active region of the main panel member. The weld joints that attach the vehicle panel assembly to the structural member are preferably located at weld openings formed in the sound-damping patch and/or the sound-damping adhesive layer so that the weld joint can be formed without melting and vaporizing the adhesive during the welding operation, as such an operation would likely require additional ventilation equipment and could impact the quality of the weld joint.

Abstract: A high-pressure fuel injection pump, including a sound-damping acoustic cover, is mounted on an engine and is part of a direct-inject fuel system for a vehicle. In an exemplary embodiment, the acoustic cover includes a top portion that fits over the fuel injection pump and a side portion that mechanically engages the fuel injection pump, and at least one of the top or side portions is formed from a sound-damping metal laminate material. Sound and/or vibrations that emanate from the fuel injection pump may be transferred to the acoustic cover and converted into thermal energy by the sound-damping metal laminate material.

Abstract: A sound-damped vehicle panel assembly, such as a dash panel, is attached to a structural member with one or more weld joints. The vehicle panel assembly may include a main panel member, a sound-damping patch, and a sound-damping adhesive layer arranged therebetween, where the patch covers at least a portion of an acoustically active region of the main panel member. The weld joints that attach the vehicle panel assembly to the structural member are preferably located at weld openings formed in the sound-damping patch and/or the sound-damping adhesive layer so that the weld joint can be formed without melting and vaporizing the adhesive during the welding operation, as such an operation would likely require additional ventilation equipment and could impact the quality of the weld joint.

Abstract: A vehicle floor tub is generally designed for attachment to a vehicle floor panel and may have a variety of uses. In one embodiment, the vehicle floor tub may include a sound damping patch applied to the base of the tub for improved vibration or sound damping purposes, thermal insulation, added structural integrity, etc. The vehicle floor tub may include a main panel, a sound damping patch, and an adhesive layer that are formed together from a main blank, a sound damping blank, and an adhesive layer. The sound damping patch may include one or more forming features located near complex stress regions.

Abstract: A multi-layer assembly, such as a sound damping metal laminate used in the automotive industry, having first and second rigid layers and an adhesive layer in between. A retention feature in the form of a raised embossment may be formed in one or more of the rigid layers and may be located near a fastening hole, which accommodates a nut and bolt or some other type of fastening device. The retention feature may impart rigidity and improved stiffness to the multi-layer assembly in the area surrounding the fastening hole, and it may also create a space between the rigid layers that is generally devoid of adhesive from the adhesive layer. This, in turn, can improve the long term performance of the multi-layer assembly by addressing issues such as compression set, spring back and/or stress relaxation. Methods of manufacture and other embodiments are also provided, including ones that accommodate multiple fastening holes, have discontinuous retention features, and use welds in place of nuts and bolts, to name a few.

Abstract: A metal panel assembly that may be used in a number of different applications, particularly those that are concerned with improved stiffness and/or reduced vibration and noise. According to an exemplary embodiment, the metal panel assembly has a multi-layer or sandwich construction and includes a metal body layer a sound damping adhesive layer, and a metal outer layer. The outer layer is bonded to the body layer via the adhesive layer and improves the stiffness and/or reduces vibrations in the metal panel assembly. The outer layer may include a number of contact sections that confront the body layer through the adhesive layer, as well as a number of raised sections that are spaced from the body layer and increase or otherwise improve the stiffness of the metal panel assembly. In one embodiment, the raised sections resemble channels and are generally arranged in a column-like pattern; in another embodiment, the raised sections resemble ribs and are generally arranged in a grid-like pattern.

Abstract: An apparatus, system and method for manufacturing metal parts, where input material is received from several material sources, multiple metal parts are produced at the same time, and the multiple metal parts may be provided to a downstream operation for subsequent processing. According to an exemplary embodiment, unwinding apparatuses unwind metal coils and provide three separate metal strips to coil-fed metal forming press. The coil-fed metal forming press then creates three separate blanks or metal parts at the same time. Next, a part transfer apparatus retrieves the three metal parts from an output side of coil-fed metal forming press, and presents them to part assembly apparatus, which may include a laser welder or other piece of equipment.

Abstract: A metal blank that includes a binder trim component having at least one cut edge with a non-linear section. The creation of the non-linear section simultaneously forms a corresponding section in a binder trim component of an adjacent metal blank so that binder material can be shared therebetween. This reduces the amount of scrap metal, as the binder trim component is subsequently cut off and discarded. Furthermore, the non-linear section can include one or more strategically placed formations, such as projections, recesses, flat sections, etc., that cause it to be non-uniform along its length and to be specifically tailored to the manufacturing requirements of the part being formed.

Abstract: A panel assembly for use in any number of different applications, including a variety of vehicle applications, that reduces noise or vibrations, provides thermal insulation, and/or improves structural integrity. According to an exemplary embodiment, the panel assembly includes a main panel made from a metal, one or more sound damping patches also made from a metal, and an adhesive layer that joins the patches to the main panel in a constrained layer construction. The sound damping patches may include one or more forming features, which are designed to improve the formability of the panel assembly without significantly impairing its sound damping characteristics. There are different types of forming features, including internal forming features (e.g., openings, holes, slits, slots, etc.) located within the interior of the patch and external forming features (e.g., projections, fingers, recesses, waveforms, etc.) located along the perimeter of the patch.

Abstract: A method of producing a composite component that includes both a structural insert and a plastic casing. According to an exemplary embodiment, the method uses a closed-loop control system and includes the following steps: evaluating the structural insert for various attributes, placing the structural insert in a mold cavity, adjusting the position and/or orientation of the structural insert with respect to the mold cavity based on, among other things, the evaluated attributes, and injecting molten material into the mold cavity so that it at least partially surrounds the structural insert.

Abstract: A metal blank that includes a binder trim component having at least one cut edge with a non-linear section. The creation of the non-linear section simultaneously forms a corresponding section in a binder trim component of an adjacent metal blank so that binder material can be shared therebetween. This reduces the amount of scrap metal, as the binder trim component is subsequently cut off and discarded. Furthermore, the non-linear section can include one or more strategically placed formations, such as projections, recesses, flat sections, etc., that cause it to be non-uniform along its length and to be specifically tailored to the manufacturing requirements of the part being formed.

Abstract: A method of removing material such as surface treatments, metal coatings, and other material layers from an edge region of a metal work piece where they could potentially contaminate a nearby weld. According to one embodiment, a scraper tool includes a body having a base portion and a tab portion, and several scraping elements attached to the base portion. During operation, the scraping elements scrape one or more surfaces of the edge region so that the depth to which the scraping element engage the metal work piece is generally affected by the amount of rotation of the scraper tool about a pivot axis.

Abstract: A sound damping material for use in a sound damping laminate having one or more rigid layers, such as those used in the automotive industry. The sound damping material is preferably a viscoelastic material that damps or otherwise inhibits the transmission of vibrational or acoustical energy through the laminate, and also acts as an adhesive for bonding the rigid layers together. In its cured form, the sound damping material layer can include an acrylate-based polymer matrix, and one or more of the following components: a precipitated phase, a viscous phase, and miscellaneous constituents. The acrylate-based polymer matrix is the reaction product of at least one acrylate-based monomer, such as isobornyl acrylate.

Abstract: A scraper tool for removing material such as surface treatments, metal coatings, and other material layers from an edge region of a metal work piece where they could potentially contaminate a nearby weld. According to one embodiment, the scraper tool includes a body having a base portion and a tab portion, and several scraping elements attached to the base portion. During operation, the scraping elements scrape one or more surfaces of the edge region so that the depth to which the scraping element engage the metal work piece is generally affected by the amount of rotation of the scraper tool about a pivot axis.

Abstract: A metal forming process and welded coil assembly that may be used to form complex metal components in a manner that is efficient, reduces scrap material, and maintains the structural integrity of the components. Generally, a number of individual metal blanks are welded to one or more sheet metal coils in order to produce a welded coil assembly. The metal blanks may be welded along the length of the inner sides of two sheet metal coils, or the metal blanks may be welded along the length of the outer sides of a single sheet metal coil, to cite a couple of possibilities. The welded coil assembly can then be fed through a progressive stamping apparatus or other machine to create a complex metal part.

Abstract: A method of producing a composite component that includes both a structural insert and a plastic casing. According to an exemplary embodiment, the method uses a closed-loop control system and includes the following steps: evaluating the structural insert for various attributes, placing the structural insert in a mold cavity, adjusting the position and/or orientation of the structural insert with respect to the mold cavity based on, among other things, the evaluated attributes, and injecting molten material into the mold cavity so that it at least partially surrounds the structural insert.

Abstract: A metal framing member for use in a wide variety of applications including interior and exterior walls, structural insulated panels (SIPs), as well as floors, ceilings and roofs of residential and commercial buildings, to name but a few. The metal framing member generally includes first and second metal components, where each of the metal components is a separate piece and includes an elongated support with a series of fingers extending therefrom. The two metal components are attached together near tips of the fingers so that an alternating sequence of fingers and spaces is formed in an intermediate area between the two supports. This sequence can result in weight, material and cost savings, reduced thermal and acoustic conductivity across the metal framing member, and trade-ready holes for passing through items such as wires, pipes, etc.

Abstract: A sound damping material for use in a sound damping laminate having one or more rigid layers, such as those used in the automotive industry. The sound damping material is preferably a viscoelastic material that damps or otherwise inhibits the transmission of vibrational or acoustical energy through the laminate, and also acts as an adhesive for bonding the rigid layers together. In its cured form, the sound damping material layer can include an acrylate-based polymer matrix, and one or more of the following components: a precipitated phase, a viscous phase, and miscellaneous constituents. The acrylate-based polymer matrix is the reaction product of at least one acrylate-based monomer, such as isobornyl acrylate.

Abstract: A metal blank that includes a binder trim component having at least one cut edge with a non-linear section. The creation of the non-linear section simultaneously forms a corresponding section in a binder trim component of an adjacent metal blank so that binder material can be shared therebetween. This reduces the amount of scrap metal, as the binder trim component is subsequently cut off and discarded. Furthermore, the non-linear section can include one or more strategically placed formations, such as projections, recesses, flat sections, etc., that cause it to be non-uniform along its length and to be specifically tailored to the manufacturing requirements of the part being formed.