Abstract: A clamp assembly for mounting a tonneau cover on a motor vehicle having a cargo area defined by first and second side walls, an end wall and a tailgate, the side walls having an inner panel and an outer panel includes a fastener, a first coupler plate and a bracket. The first coupler plate has a first end and a second end. The first coupler plate is articulable from an operable position to a disengaged position. The bracket has a generally horizontal rail and a vertical rail. The bracket is adapted for contacting the outer panel of the first side wall and further has a seat pivotally retaining the first end of the first coupler plate. The second end of the first coupler plate is adapted for engaging the inner panel of the first side wall defining a first restraining area between the horizontal rail and the second end of the first coupler plate. A second restraining area between the vertical rail and the second end of the first coupler plate is also defined.

Abstract: A method for adhesively joining two members includes the steps of mixing non-compressible beads with an adhesive, applying the resulting mixture to one of the members and hemming one member over the other in overlapping relationship. Apparatus for performing this method includes a container for containing a mixture of an adhesive and a plurality of non-compressible beads, an applicator for applying the mixture to one of the members, and hemming means for hemming one member over the other in overlapping relationship. A metering device for dispensing adhesive fluid is constructed with a dispensing rod having a cooling means for facilitating operation of the metering device. The present invention finds particular utility in bonding together the inner and outer panels of an automotive door assembly.

Abstract: The present invention provides an apparatus for manufacturing sheet molding compound comprising a fiber processing unit for forming a fiber web. The apparatus also includes a precompaction unit for squeezing air out of the fiber web and a resin mixture paste dispenser for applying paste to the fiber web. The apparatus functions to minimize entrapped air from the resin mixture paste and fiber web.

Abstract: A vehicle frame is provided including a pair of frame rails. A rear suspension support assembly extends between the pair of frame rails. The rear suspension support assembly includes a rear suspension crossmember having first and second ends each attached to one of the frame rails. A pair of spring brackets are attached to the rear suspension crossmember and to the frame rails. The rear suspension support assembly has a generally X-shaped configuration which improves the frame stiffness.

Abstract: A transfer/injection molding apparatus is defined that includes a charge forming unit, a molding unit and a charge overflow unit. The charge is formed so that the fibers therein are randomly oriented in substantially parallel horizontal planes such that they are always substantially parallel to the direction of initial flow into the cavity of the molding unit. Excess charge from the cavity is forced into the charge overflow unit, which is selectively located in an area where surface finish is less critical. The excess charge displaces an overflow pin, which is kept upwardly biased, under molding pressure, to be flush with the lower inside wall of the molding unit cavity.

Abstract: The present invention provides an apparatus and method for manufacturing sheet molding compound including a fiber processing unit for forming a fiber web, and a vacuum chamber unit having a resin paste dispenser, wherein the paste is applied to the fiber web within the vacuum chamber for minimizing entrapped air within the compound.

Abstract: An automated method for controlling the amount of charge introduced in a mold having a mold cavity and associated overflow assembly by adjusting the amount of charge introduced into the mold cavity in subsequent moldings using a measurement of the amount of excess charge material received by the overflow assembly. The charge is formed so that the fibers therein are randomly oriented in substantially parallel horizontal planes such that they are always substantially parallel to the direction of initial flow into the cavity of the molding unit. Excess charge from the cavity is forced into the charge overflow unit, which is selectively located in an area where surface finish is less critical. The excess charge displaces an overflow pin, which is kept upwardly biased, under molding pressure, to be flush with the lower inside wall of the molding unit cavity. The pin displacement is measured by a sensing transducer.

Abstract: A hydroformed control arm for a vehicle and a method of making the same is provided. The control arm includes a generally U-shaped member being hydroformed from a continuous, unitary tube. The generally U-shaped member includes varying cross-sectional areas along its length for improved structural integrity. The generally U-shaped member further includes a pair of pivot bores for enabling the control arm to pivot about a pivot axis. The U-shaped member still further including a ball joint cavity disposed near its apex for receiving a ball joint. The hydroformed control arm thereby eliminates the need for a ball joint bushing.

Abstract: An efficient, low cost method and apparatus for controlling fiber deposition in a fiber reinforced preform is provided. In the method, a main screen is placed in a tank filled with liquid. The main screen has a major surface, upright side walls and a plurality of openings formed therein. Reinforcing fibers are added to the liquid to create a slurry. The main screen is raised through the slurry to a level beneath the top of the slurry, thereby causing the reinforcing fibers to be deposited on the main screen. A retainer screen is inserted into the slurry so that the reinforcing fibers are sandwiched between the main screen and the retainer screen. Both the main screen and retainer screen are raised out of the tank effectively forming a preform with minimal deformation. An alternative embodiment includes a bubbler zone control device for mixing the slurry. The tank is divided into separate areas or zones whereby the supply of fluid to each bubbler zone is controlled.

Abstract: A method for adhesively joining two members includes the steps of mixing non-compressible beads with an adhesive, applying the resulting mixture to one of the members and hemming one member over the other in overlapping relationship. Apparatus for performing this method includes a container for containing a mixture of an adhesive and a plurality of non-compressible beads, an applicator for applying the mixture to one of the members, and hemming means for hemming one member over the other in overlapping relationship. A metering device for dispensing adhesive fluid is constructed with a dispensing rod having a cooling means for facilitating operation of the metering device. The present invention finds particular utility in bonding together the inner and outer panels of an automotive door assembly.

Abstract: A process for forming angled trim lines on vehicle frame cross members to mate and secure the ends of the cross members with frame side rail members with a high degree of accuracy and in a cost efficient manner. The process includes the steps of removing portions of the end of a rectangular tube to form angled trim lines and connecting the angled trim lines with the frame side rail member. A cam trimming die is used to form the angled trim lines. The die includes substantially symmetrical drivers, slide cams, and filler cams. The drivers move the slide cams and filler cams in opposing directions. The slide cams carry cutting steels that form the angled trim lines as the slide cam moves. The filler cams support the rectangular tube and produce a sheering effect with the cutting steels as they move past one another.

Abstract: The present invention provides a material forming tool, such as a sheet metal stamping die, having a polymer matrix and filler material mixed therein. The filler material is a plurality of microspheres which are coated with a release agent. The coating of the release agent should be sufficient to allow the microspheres to rotate in the polymer matrix when the tool is used to form material.

Abstract: A method is provided for forming an elongated multi-lateral member from a round tube. A die is provided having a first die member and a second die member movable relative to the first die member between open and closed positions. The first and second die members define a first pair of opposed surfaces which each lie in a plane angled slightly with respect to an axis of movement of the second die member. The first and second die members further define a second pair of opposed surfaces which lie in a plane generally perpendicular to the first pair of opposed surfaces and which combine with the first pair of opposed surfaces to define a die cavity.

Abstract: A multi-piece hydroforming tool is provided having a tooling die and a hydraulic pressure source. The tooling die includes a plurality of tooling cavities. Each tooling cavity includes a injector manifold in fluid communication with the hydraulic pressure source. The injector manifolds supply pressurized hydraulic fluid to each of the plurality of tooling cavities independently. Thus, multiple pieces may be formed simultaneously and independently, thereby minimizing the need to discard all the hydroformed pieces if one piece become defective.

Abstract: A body bracket is provided for attachment to a vehicle frame. The body bracket includes a top wall having an attachment hole therein. A pair of sidewalls extend from the top wall. The sidewalls include an upper end and a lower end. The sidewalls are flared such that a distance between the lower ends of the pair of sidewalls is larger than a distance between the upper ends thereof. The sidewalls have an end portion for attachment to the vehicle frame. The end portions are provided with an outward taper.

Abstract: The present invention provides an electrically conductive sheet molding compound composition adapted for electrostatic painting comprising a resin mixture including about 20 to about 60% by weight of thermoplastic resin based on the total weight of said resin mixture, the thermoplastic resin being selected from the group consisting of styrene-butadiene rubber, polystyrene, saturated polyester resin, and mixtures thereof; fibrous reinforcing material; and conductive material. The conductive material is added to the sheet molding compound composition in a sufficient quantity to render an article molded with said composition with structural integrity and electrically conductive enough to be electrostatically painted.

Abstract: A forming device including discreet heating zones along the axial length and circumferential portion of a mold cavity. One zone can be heated to cause the heated tube portion to become more elastic than the non-heated tube portions. As a result, less axial force and radial pressures are required in order to provide the necessary metal deformation against the mold halves. Preferably, the heating zones are provided by way of a series of induction coils disposed along the axial length and circumferential portion of the tube. Each induction coil can be individually energized so that select portions of the tube are heated in a controlled manner.

Abstract: An efficient, low cost method and apparatus for controlling fiber deposition in a fiber reinforced preform is provided. In the method, a main screen is placed in a tank filled with liquid. The main screen has a major surface, upright side walls and a plurality of openings formed therein. Reinforcing fibers are added to the liquid to create a slurry. The main screen is raised through the slurry to a level beneath the top of the slurry, thereby causing the reinforcing fibers to be deposited on the main screen. A retainer screen is inserted into the slurry so that the reinforcing fibers are sandwiched between the main screen and the retainer screen. Both the main screen and retainer screen are raised out of the tank effectively forming a preform with minimal deformation. An alternative embodiment includes a bubbler zone control device for mixing the slurry. The tank is divided into separate areas or zones whereby the supply of fluid to each bubbler zone is controlled.

Abstract: A composite fiber reinforced plastic (FRP) bumper includes an energy absorbing outer shell which is spaced from a rigid inner beam. The outer shell deforms under low impact loads and serves as an energy absorber. Upon high impact loads, the shell abuts the inner beam which, in turn, transfers the loads to the vehicle frame.

Abstract: An automated transfer/injection molding apparatus and process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.