Abstract: A composite brake drum particularly adapted for motor vehicle applications. The brake drum includes a reiforcement assembly enclosed within the cylindrical portion of the drum. The reinforcement assembly is preferably made from steel wire stock and includes a plurality of circular loops spaced axially within the brake drum cylindrical portion. Axially extending locator wires are mechanically fastened to the reinforcing loops and serve to locate the loops. End portions on the locator wire contact only one of the mold halves forming the mold cavity and enable the device to be essentially self-locating without crossing the parting line of the mold. By not crossing the parting line, the position of the loops is maintained within acceptable tolerance limits from the finished friction surface of the drum.

Abstract: Molded articles prepared from flexible sheet molding compounds, and method of making the same. A flexibility modifying agent is incorporated into a thermoset resin composition (e.g. sheet molding compound) to improve the flexiblity characteristics of the thermoset resin compositon by lowering the flexural modulus. The thermoset resin composition also contains therein an isocyanate terminated urethane prepolymer; a thickening agent; a catalyst; a fibrous reinforcing material; and an inert filler.

Abstract: An energy absorbing structure for a vehicle door includes an elongated resin reinforced member disposed horizontally between the inner and outer panels of a vehicle door. The elongated member includes first and second enlarged ends, each having an outwardly diverging surface. The elongated member is supported at either end by first and second support members which attach to the vehicle door frame. The support members both include female receptacles having a compatible taper which allows them to mate with the respective enlarged end of the elongated member. The energy absorbing structure absorbs energy imparted laterally upon a vehicle door during side impact through deflection of the elongated member and additionally through distortion of the first and second support members.

Abstract: A method and apparatus for making fiber reinforced plastic preforms via a wet slurry process. A screen with the desired preform configuration is placed in the bottom of a tank. The tank is then filled with water and chopped fibers to create a slurry. The screen is raised up through the slurry causing fibers to be deposited on the screen in the shape of the preform. The preform is then removed from the screen, placed in a mold and injected with resin to form the desired structure.

Abstract: Disclosed is a universal system for the support and positioning of a workpiece for use with a device such as an inspection system. A plurality of individual alignment devices are inserted into predetermined holes of a platform having a matrix of holes. Functions of individual alignment devices include support, clamping, datum point positioning and providing reference points. Each alignment device usually includes stanchions of varying length. Each stanchion is capable of being connected to another stanchion. Once the alignment device is positioned in a hole it can be fine tuned in all directions to get an exact location. Workpieces of widely varying types, shapes and sizes can thus be positioned using the same set of alignment devices.

Abstract: A vehicle hub and bearing assembly which includes a sensor for use with an anti-lock braking system (ABS). The hub and bearing assembly includes a hub which rotates relative to a bearing pack assembly adapted to be mounted to a steering knuckle to other suspension component. A sensor exciter ring is fit onto the hub and rotates with the hub upon wheel rotation. An ABS sensor is mounted directly to specially formed mounting features defined by the projecting mounting flange of the bearing pack. With the sensor being mounted directly to the bearing pack, an accurate radial clearance between the exciter ring and sensor can be provided with a minimal number of assembled components defining the radial clearance. This design provides enhanced control over sensor radial clearance, tends to maintain radial clearance for a longer period of time, and allows radial clearance to be set for the hub and bearing sub-assembly which does not require subsequent adjustment by the motor vehicle manufacturer.

Abstract: A hollow fiber reinforced part, especially body closures for vehicles, is made by applying preforms to a hollow, thin-walled support which has been preshaped to the general configuration of the body closure. The support is then depressurized and the support/preform subassembly placed into a mold. The mold is closed and the support again pressurized. Then, resin is injected into the mold to impregnate the fibrous pieces of the preforms. Once the resin cures, the mold is opened and the part removed.

Abstract: Surface imperfections on painted fiber reinforced plastic (FRP) automotive body panels are substantially eliminated by incorporating thermally conductive material into the part that serves to minimize temperature differentials on the surface of the part to be painted.

Abstract: A method is disclosed for recycling reinforced plastic composite materials. The reinforced plastic composite material is heated to separate said plastic matrix material from said reinforcement material. At least the separated reinforcement material is recycled. The products produced by these methods and processes are also disclosed.

Abstract: A modular electrical power cord system that finds particular utility for use in truck engines having at least two engine block heaters. A primary cord is used with one of a plurality of different jumper cords whose length most closely matches the distance between the heaters.

Abstract: A method and apparatus is disclosed for bonding fiber reinforced plastic automotive body parts to reinforcement members using dielectric heating.

Abstract: A method and apparatus is disclosed for bonding fiber reinforced plastic exterior automotive body panels to reinforcement members using dielectric heating.

Abstract: A combination transfer/turnover machine has a pair of double-acting transfer arms for quickly retrieving and inserting parts into a pair of metal stamping presses performing sequential operations on a workpiece. A turnover mechanism is provided for inverting the part during its transfer between machines. The transfer arm and turnover mechanism are all carried by a horizontally and vertically moveable bar mounted to a carriage. The entire apparatus can be mounted as a single unit to overhead support structure in a factory between the machines.

Abstract: A method of molding in a single operation an integral fiber structure including a hollow resin impregnated fiber section. A fibrous material is placed in a mold having a hollow section formed by a first mold part and a second mold part formed by second complementary surface portions extending from the hollow first mold part. An inflatable member is placed in the mold in the cavity and inflated. Resin is injected into the fibrous material between the second complementary mold surface portions and flows toward the cavity to impregnate all of the fibrous material. The resin is cured to form a fiber reinforced structure with a sheet-like portion joined to the hollow section.

Abstract: Kicker cylinders are used in a vacuum compression molding method and apparatus to initially break the seal between two members of the mold in order to facilitate quick opening of the mold to thereby increase part cycle time.

Abstract: A hollow fiber reinforced structure having irregular cross-sections, curvatures, joints and twists is provided. A method of forming the structure includes placing fibrous material on the walls of an outer mold and placing a bladder internal to the fibrous material, which serves as an inner mold. When the mold is closed and the bladder expanded, resin is injected into the fibrous material. After curing, the solid reinforced structure is formed.

Abstract: A composite brake drum particularly adapted for motor vehicle applications. The brake drum includes a reinforcement assembly embedded within the cylindrical portion of the drum. The reinforcement assembly is preferably made from steel wire stock and includes a plurality of circular closed rings spaced axially within the brake drum cylindrical portion. axially extending locator wires are mechanically fastened to the reinforcing rings and serve to locate the rings. Loops can be formed on the locator wires for positioning the reinforcement assembly within a casting mold cavity to enable the device to be essentially self-locating within the mold. The composite brake drum is fabricated by pouring iron into the mold and then finish machining operations are performed.

Abstract: A method for making a part with a smooth surface, such as an exterior automotive body panel, by compression molding a charge containing a curable resin. The charge is placed on the molding surface of one of the dies of a compression mold so that the charge covers 40%-80% of the surface area of the molding surface. The molds are moved to a partially closed position and the mold cavity is quickly evacuated. The mold is then closed so that the dies compress the charge to cause it to fill the mold cavity and, after the resin cures, the part is removed from the mold.

Abstract: A one-piece push rod and method of making same is provided which includes the step of swaging ends of a hollow tube so that end portions have been reduced to 90%-50% of the starting stock. Preferably, the tube is characterized by a thicker middle portion which tapers down to the ends of reduced diameter. Spherical seats of constant wall thickness are formed by first machining a taper on the tips and then cold forming the tapered tips with a punch.

Abstract: The clamping mechanism for securing in place an electric heating element insertable through a frost plug aperture into the coolant passage in the blocks of a water cooled internal combustion engine includes a screw having a head located on the outside of a removable body member carrying the heating element, which body member is adapted to be inserted into the apertures to sealingly close it against leakage. The inner end of the screw extends freely through an opening formed in a bight portion connecting a pair of opposed side walls of a rigid yoke having a length greater than the largest dimension of the aperture and adapted to engage the inner surface of the block around the aperture and is threaded into a nut loosely captivated within the yoke by the bight portion, side walls and detents extending inwardly from the side walls and overlying the bight portion. The yoke opening is so sized and the detents are so arranged that the rigid yoke may be tilted about the screw to enter the block through the aperture.