Abstract: In accordance with the teachings of the present invention, there is provided a door closure apparatus for covering a single opening in a vehicle body. The apparatus including a first door, a second door and a third door, each door being pivotally supported by hinges which are concealed from view when the first, second, and third doors are in a closed position.

Abstract: In accordance with the teachings of the present invention, a vehicle door including fiber reinforced plastic (FRP) members is provided. The vehicle door includes a fiber reinforced plastic outer skin member which is adhesively bonded to a fiber reinforced plastic intermediate shell including lateral side walls cooperating with inner and outer faces to define an open box-like structure with a hollow, interior cavity. The adhesively bonded outer skin member and intermediate shell define a door subassembly to which a hinge mechanism is coupled for securement to a body of a partially assembled vehicle. The door subassembly and the body of the partially assembled vehicle are simultaneously painted during the on-line assembly process.

Abstract: The present invention provides a windshield frame utilizing composite technology. More particularly, the windshield frame preferably comprises a fiber reinforced plastic molded upper frame section bonded with a structural grade adhesive to a fiber reinforced plastic molded lower frame section. According to the invention, steel reinforcements and tapping plates are bonded on or molded into the frame sections to stabilize the structure and provide hardware attachment points. Continuous carbon fibers may also be molded in the frame sections in critical high stress areas. The strength of the bonding between the frame sections is enhanced by a tongue and groove geometry along the interface. In addition, dowel pins and bushings are used to mechanically tie the frame sections together near body side attachment points.

Abstract: A vehicle frame having a side/cross member joint, including a pair of side members each having at least one opening therethrough, the openings having a plurality of generally straight edge portions. A cross member is connected to the side members, wherein the one cross member is disposed in the openings in the side members. The cross member is deformed radially outwardly such that an outer surface of the cross member is formed with a pair of grooves having radially extending walls on opposite sides of each of the openings in the side member. A plurality of flat and semi-circular portions are formed in the cross member corresponding with the straight edge portions and the semi-circular edge portions of the openings.

Abstract: A method and apparatus for binding the fibers of, and forming a fiber reinforced plastic structure. A fiber reinforced plastic preform is created by depositing a mixture of reinforcing fibers, binding fibers and resin matrix fibers on a screen having a preselected geometry. The fiber reinforced plastic preform is exposed to high temperature fluid causing the binding fibers to melt and, thereafter, to cool air to temporarily bind the preform in a tackified state. The tackified preform is exposed to a higher temperature fluid causing the resin matrix fibers to melt and, thereafter, to cool air to solidify and thus bind and lock the reinforcing fibers of the tackified preform in place to create a homogeneous fiber reinforced plastic structure.

Abstract: A method and apparatus of producing and using composite fibers in a liquid molding process. The composite fibers are formed from a base material and filler particles which are lighter or less expensive than the base material. A preform screen is placed at the bottom of a tank. The tank is filled with liquid, the composite fibers and a mass of reinforcing fibers creating a slurry above the screen. The screen is raised up through the slurry causing the composite fibers and the reinforcing fibers to be deposited on the screen creating a fiber preform. The preform is then removed from the screen and is placed in a mold for use in a liquid molding process.

Abstract: An apparatus for making fiber reinforced preforms using a wet slurry process wherein the flow of liquid through portions of a screen having a predetermined configuration is selectively controlled. The selective control of the flow of liquid through the portions of the screens regulating the quantity of fibers deposited on the selected portions of the screen thereby controlling the thickness of the fiber preform at the selected portions of the screen.

Abstract: A container having a mixture of one part of a two-part epoxy adhesive with a plurality of glass beads pre-mixed therein. The concentration of beads in the final mixture as applied to the joint to be bonded is in the range of about 5% to about 20% by weight, with the beads having a diameter in the range of 0.003 to about 0.030 inches. The mixture is capable of being pumped from the container and applied to a member for forming a hem flange joint with another member. The adhesive/glass beads mixture finds particular utility to help prevent excess squeeze out and promote reliable bonds in processes in which an inner and outer panel of an exterior automotive closure member are joined together by way of a hem flange.

Abstract: A method and apparatus for binding the fibers of a fiber reinforced plastic preform. A fiber reinforced plastic preform is created in a preselected geometry from a mixture of reinforcing fibers and binding fibers, the binding fibers being responsive to a high frequency electromagnetic field to melt thereby binding the reinforcing fibers. The fiber reinforced plastic preform is then exposed for a short period of time to a high frequency electromagnetic field, with the high frequency electromagnetic field causing the binding fibers to melt thus binding the reinforcing fibers of the preform.

Abstract: An automated transfer/injection 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.

Abstract: A method and apparatus for binding the fibers of a fiber reinforced plastic preform. A fiber reinforced plastic preform is created in a preselected geometry from a mixture of reinforcing fibers and binding material. The fiber reinforced plastic preform is sequentially exposed to high temperature steam and cool air causing the binding material first to melt and, thereafter, to solidify thus binding and locking the reinforcing fibers of the preform in place. The fiber reinforced plastic preform is ejected from the apparatus by air pressure and is retrieved by any suitable method.

Abstract: In accordance with the teachings of the present invention, a vehicle hood including fiber reinforced plastic (FRP) panels is provided. The vehicle hood includes a fiber reinforced plastic hood outer panel bonded to a fiber reinforced plastic hood inner panel including a pair of depressions extending toward the hood outer panel. Each depression includes a projection extending away from the hood outer panel which is aligned with a hood bumper. The bonded hood outer panel and hood inner panel define a hood assembly which includes mechanisms for attachment to a vehicle, the mechanisms including a pair of hinge assemblies, a latch assembly, and a latch reinforcement member. Metal reinforcement members may be secured to the hood inner panel for structural reinforcement of the hood assembly.

Abstract: A method of molding an outer body panel and attaching that outer panel to an inner supporting portion of a vehicle. The outer panel is made in a mold having a mold cavity and a plurality of passages extending outwardly from the cavity. During the molding process, ejector pins disposed within these passages are used to provide supplemental pressure within the mold cavity and prevent shrinkage. After the material within the mold has solidified, the mold is opened and the ejector pins are used to eject the outer panel from the mold. Locating members formed in the passages are used to locate and maintain the outer panel in a fixed relationship with respect to the inner supporting portion when they are assembled and bonded to one another.

Abstract: A hybrid vehicle assembly, and more particularly, a hybrid truck assembly including a hybrid passenger cab shell and a hybrid truck box are disclosed. The hybrid passenger cab shell includes a first plurality panels which are assembled together to form an inner cab shell and a second plurality of panels which are assembled together to form an outer cab shell. Generally, at least one of the first or second pluralities of panels are formed from a plastic material such as a sheet molded compound (SMC). Similarly, the truck box portion of the vehicle is formed from a plurality of inner panels which are formed from a plastic material such as SMC and are assembled together along overlapping edge portions. Thereafter, a plurality of outer panels are attached to the respective inner panels.

Abstract: A one-piece cast suspension mounting spring pocket having a circular, radially contoured disk portion and having a plurality of flanges is disclosed. The disk portion serves as a spring pocket and prevents a spring from radial movement. The flanges are parallel to and spaced from one another, and are generally perpendicular to the disk portion of the one-piece cast member. One or more of the flanges intersects a frusto-conical formation which is radially centered in the disk portion, the intersecting flange conforming to and bowing with the frusto-conical formation. The structural integrity of the one-piece cast spring pocket is improved when compared to the currently produced multi-piece spring pockets by having the flange intersect the frusto-conical section.

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 apparatus 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 apparatus 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: An axle assembly for a motor vehicle of the type including a rigid drive axle and a rigid axle tube extending between a drive axle differential to the axle wheel end. The axle tube features a radial flange defining an outboard facing bearing retention shoulder. A bearing carrier unit is bolted onto the axle tube flange to trap the bearing outer race. The axle shaft engages the bearing inner race which is trapped between a flange on the axle shaft and a nut threaded onto the axle. This wheel and system provides improved wheel run-out characteristics which are advantageous for disk brake applications and facilitates the use of anti-lock braking system wheel speed sensors.

Abstract: An apparatus and method is disclosed for bonding a fiber reinforced plastic automotive body member to a reinforcement member. An adhesive is located between mating surfaces of the body member and the reinforcement member. Pressurized heated and cool air is used to heat and facilitate the cooling of the adhesive. The apparatus includes a switchable heating and cooling system that first provides pressurized heated air about outer surfaces of the body member and the reinforcement member, and thereafter, the system provides pressurized cool air about the same outer surfaces.