Abstract: A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

Abstract: An exhaust module made of a thermoplastic material which is connected to a fascia or bumper of a vehicle. In one embodiment, the hybrid fascia mounted exhaust tip assembly includes a bracket. The bracket has a large diameter portion which surrounds, but is not in contact with, an exhaust pipe. The exhaust pipe is free to move around as a result of the vehicle traveling over bumps in the road and around turns. The bracket also has a small diameter portion which is connected to the large diameter portion. A ring tip has a portion that slides onto a bezel portion of the small diameter portion.

Abstract: A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

Abstract: An exhaust module made of a thermoplastic material which is connected to a fascia or bumper of a vehicle. In one embodiment, the hybrid fascia mounted exhaust tip assembly includes a bracket. The bracket has a large diameter portion which surrounds, but is not in contact with, an exhaust pipe. The exhaust pipe is free to move around as a result of the vehicle traveling over bumps in the road and around turns. The bracket also has a small diameter portion which is connected to the large diameter portion. A ring tip has a portion that slides onto a bezel portion of the small diameter portion.

Abstract: An exhaust module made of a thermoplastic material which is connected to a fascia or bumper of a vehicle. In one embodiment, the hybrid fascia mounted exhaust tip assembly includes a bracket. The bracket has a large diameter portion which surrounds, but is not in contact with, an exhaust pipe. The exhaust pipe is free to move around as a result of the vehicle traveling over bumps in the road and around turns. The bracket also has a small diameter portion which is connected to the large diameter portion. A ring tip has a portion that slides onto a bezel portion of the small diameter portion.

Abstract: A novel method and set of structures for performing resistive implant welding of two plastic components to form an assembly. A first one of the components to be welded includes a channel structure which receives the resistive implant and maintains it in a desired position until the welding operation is performed. The second component to be welded includes a complementary structure including a land which is sized to engage the channel structure and captive resistive implant on the first component. The two components are pre-weld positioned with the land in the channel structure and the positioned components are then placed in a press which exerts a pre-selected pressure on the interface between the channel and the land. Next, a pre-selected electric current is passed through the resistive implant to heat it and to bring the plastic material of the channel structure and the land to their molten points, where they intermingle through the resistive implant.

Abstract: An exhaust module made of a thermoplastic material which is connected to a fascia or bumper of a vehicle. In one embodiment, the hybrid fascia mounted exhaust tip assembly includes a bracket. The bracket has a large diameter portion which surrounds, but is not in contact with, an exhaust pipe. The exhaust pipe is free to move around as a result of the vehicle traveling over bumps in the road and around turns. The bracket also has a small diameter portion which is connected to the large diameter portion. A ring tip has a portion that slides onto a bezel portion of the small diameter portion.

Abstract: An implant applicator and method for positioning a resistive implant material on a first plastic component to be used to form a resistive implant weld between that first plastic component and a second plastic component. The resistive implant material is heated and pressed into a targeted surface of the first plastic component to tack the resistive implant into place. The second plastic component is positioned over the tacked resistive implant and a weld formed in a known manner. The resistive implant material can be heated for tacking by passing an electric current through it before it is pressed into the first plastic component by a second member or by contacting the resistive implant material against a separately heated surface prior to pressing it into the first plastic component.

Abstract: An implant applicator and method for positioning a resistive implant material on a first plastic component to be used to form a resistive implant weld between that first plastic component and a second plastic component. The resistive implant material is heated and pressed into a targeted surface of the first plastic component to tack the resistive implant into place. The second plastic component is positioned over the tacked resistive implant and a weld formed in a known manner. The resistive implant material can be heated for tacking by passing an electric current through it before it is pressed into the first plastic component by a second member or by contacting the resistive implant material against a separately heated surface prior to pressing it into the first plastic component.

Abstract: A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

Abstract: A bracket assembly including a plurality of components attached along a hem line, a plurality of attachment points along the hem line, a first bracket, and a second bracket. The first bracket connects to the plurality of components at at least one of the plurality of attachment points, and supports a longitudinal load applied to at least one of the plurality of components. The second bracket connects to the plurality of components, and supports a lateral load applied to at least one of the plurality of components.

Abstract: A bracket assembly including a plurality of components attached along a hem line, a plurality of attachment points along the hem line, a first bracket, and a second bracket. The first bracket connects to the plurality of components at least one of the plurality of attachment points, and supports a longitudinal load applied to at least one of the plurality of components. The second bracket connects to the plurality of components, and supports a lateral load applied to at least one of the plurality of components.

Abstract: A tailgate assembly for a motor vehicle includes an outer panel, an integrally formed inner structural panel, and at least one reinforcing panel. The inner structural panel is coupled to the outer panel and includes a support surface facing the outer panel. The inner structural panel also includes spaced apart upper and lower walls extending laterally along the support surface, a pair of end walls extending between the upper and lower walls, and a plurality of ribs spaced apart and disposed between the upper and lower walls. The plurality of ribs also extends laterally between the end walls. The reinforcing panel is disposed between the outer and inner structural panels. The reinforcing panel is secured to the integrally formed inner structural panel between a portion of the plurality of ribs to add rigidity to the tailgate assembly.

Abstract: A tailgate assembly for a motor vehicle includes an outer panel, an integrally formed inner structural panel, and at least one reinforcing panel. The inner structural panel is coupled to the outer panel and includes a support surface facing the outer panel. The inner structural panel also includes spaced apart upper and lower walls extending laterally along the support surface, a pair of end walls extending between the upper and lower walls, and a plurality of ribs spaced apart and disposed between the upper and lower walls. The plurality of ribs also extends laterally between the end walls. The reinforcing panel is disposed between the outer and inner structural panels. The reinforcing panel is secured to the integrally formed inner structural panel between a portion of the plurality of ribs to add rigidity to the tailgate assembly.

Abstract: A tonneau cover (10) for use on automotive vehicle has a plurality of panels (12, 14, 16). Each panel has a leading edge and a trailing edge configured to interlock with an adjacent panel. A pair of rails (18, 20) are mounted on opposite side walls (38, 40) of the vehicle in a position to support the panels. Each of the rails has a pivotally mounted plate (44) which pivots between a storage condition enabling the panels (12, 14, 16) to be received and stored between the rails and an operative condition supporting the panels. A plurality of latch assemblies (22, 42) operatively extends between each of the panels and each of the pair of rails. The latch assemblies (22, 42) selectively secure the plurality of panels (12, 14, 16) to the rails (18, 20).

Abstract: A tonneau cover (10) for use on automotive vehicle has a plurality of panels (12, 14, 16). Each panel has a leading edge and a trailing edge configured to interlock with an adjacent panel. A pair of rails (18, 20) are mounted on opposite side walls (38, 40) of the vehicle in a position to support the panels. Each of the rails has a pivotally mounted plate (44) which pivots between a storage condition enabling the panels (12, 14, 16) to be received and stored between the rails and an operative condition supporting the panels. A plurality of latch assemblies (22, 42) operatively extends between each of the panels and each of the pair of rails. The latch assemblies (22, 42) selectively secure the plurality of panels (12, 14, 16) to the rails (18, 20).