Abstract: A deep-drawn, marine hull having a sandwich structure with a cellulose-based core and watercraft utilizing same are provided. The hull includes an outer skin of a fiber-based thermoplastic and having a waterproof outer surface, a first sheet of thermoplastic adhesive, an inner skin of a fiber-reinforced thermoplastic material and having a compartment-defining outer surface, a second sheet of thermoplastic adhesive and a shock absorbing, cellular core of a cellulose-based material and positioned between the skins The skins are bonded to the core by the first and second sheets and by press molding. Cells of the cellular core absorb energy of an impact at the outer surface of the outer skin by deformably crushing. Air trapped within cells which are not completely crushed or punctured by the impact provide the hull with buoyancy to allow the hull to float at the surface of a body of water.

Abstract: An assembly including a compression-molded, composite panel having first and second outer layers of fiber-reinforced thermoplastic material, first and second sheets of thermoplastic adhesive and a core of cellulose-based material is provided. The core has first and second portions positioned between the outer layers. The second outer layer is bonded to the core by the second sheet by press molding. The first outer layer includes a first portion bonded to the first portion of the core by the first sheet by press molding and a second portion bonded to the second portion of the core to form a mounting flange pivotally connected to the first portion of the first outer layer. A component is mounted to the flange to pivot with the flange. A living hinge allows the flange and the mounted component to pivot between different use positions relative to the first portion of the first outer layer.

Abstract: A method of making a sandwich-type composite panel having a cellulose-based core and a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based cellular core disposed between the sheets and the skins. A pressure is applied to the stack after heating the stack wherein the skins are bonded to the core by the sheets to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with applying the pressure to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel. The heated first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge.

Abstract: A cargo management system including a vehicle load floor having a cellulose-based core to compartmentalize a cargo area of the vehicle into an upper compartment and a covered lower compartment is provided. The floor has a wood grain finish. The load floor includes a compression-molded composite panel that includes first and second outer layers of fiber-reinforced thermoplastic material, first and second sheets of thermoplastic adhesive and a core of cellulose-based material and positioned between the outer layers. The core has a large number of cavities. The outer layers are bonded to the core by the first and second sheets and by press molding. The first outer layer having a top surface on which a multi-layer sheet is bonded by the press molding. The multi-layer sheet has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish.

Abstract: A method of bonding a thermoplastic component to a carpeted component is provided. The method includes providing a base component, a thermoplastic component and a fibrous carpet or mat between the components. The carpet has a large number of cavities. The carpet is made of a thermoplastic material adapted to bond to the thermoplastic component in response to heat at the interface between the thermoplastic component and the carpet. The method also includes heating the thermoplastic component and the carpet at the interface between the thermoplastic component and the carpet for a period of time to soften the carpet. The method finally includes pressing the components and the softened carpet together under a pressure to cause the softened carpet to flow and at least partially fill the cavities. The carpet at the interface is transformed into a solid bonding layer to bond the components together to create a finished structure.

Abstract: A method of making a sandwich-type composite panel having a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins heated to a softening temperature and a thermoplastic cellular core disposed between the skins. The first skin is stretchable when heated to the softening temperature. A pressure is applied to the stack after the step of heating to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel and a crushed portion of the panel between the two side portions. The first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge.

Abstract: A cargo management system including an automotive vehicle seat having a backrest which separates the vehicle interior into a passenger area at the front of the vehicle and a cargo area at the rear of the vehicle is provided. The system includes a vehicle load floor which includes first and second outer layers and a core of cellulose-based material positioned between the outer layers and having a large number of cavities. The outer layers of the load floor are bonded to the core by press molding. The load floor has a wood grain finish. A compression-molded, composite cargo trim panel is secured to the backrest and includes a base layer and a coverstock sheet bonded to the base layer by press molding. The coverstock sheet provides the trim panel with a wood grain finish in an upper compartment of the cargo area.

Abstract: An automated method and system for making painted vehicle body panel skins and vehicle body panels. The method includes transferring a mold having a mold surface from an entrance station to a paint station within a dispensing area. The method further includes applying paint on the mold surface to form a layer of paint on the mold surface at the paint station. The method still further includes spraying curable polyurethane elastomer on the painted surface at a spray station within the dispensing area. The paint and spray stations may be coincident. The method still further includes, after the step of spraying and while the polyurethane elastomer is uncured, transferring the mold with the paint and the uncured polyurethane elastomer from the spray station to at least one accumulator station in a curing area to allow the polyurethane elastomer to completely cure in the mold and form the skin.

Abstract: A method of molding composite plastic sheet material to form a compression molded, deep-drawn article is provided. The method includes placing a heated blank of moldable, composite plastic sheet material over a female die having an article-defining cavity defined by inner surfaces of the die so that the heated blank has a predetermined position and orientation over the cavity. Then an inner portion of the heated blank is forced into the cavity along a substantially vertical axis and against the inner surfaces of the die to obtain deep-drawn material. Outer peripheral portions of the heated blank adjacent the cavity are controllably held with corresponding predetermined holding forces based on the size and shape of the article to resist movement of the outer peripheral portions towards the cavity during the step of forcing wherein the deep-drawn material controllably stretches during the step of forcing without wrinkling, tearing or ripping.

Abstract: A cargo management system including a vehicle load floor and a pair of opposing cargo trim panels supported above the load floor at opposite sides of the load floor within the interior of the vehicle is provided. The load floor has a wood grain finish. The load floor includes a first outer layer, a second outer layer and a core of cellulose-based material positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. The trim panels are compression-molded, composite cargo trim panels supported above the vehicle load floor at opposite sides of the load floor. Each panel includes a base layer and a coverstock sheet bonded to the base layer by press molding. Each coverstock sheet provides its respective trim panel with a wood grain finish.

Abstract: A cargo management system including a vehicle load floor to compartmentalize a cargo area of the vehicle into an upper compartment and a covered lower compartment is provided. The floor has a wood grain finish. The load floor includes a compression-molded composite panel that includes first and second outer layers and a core positioned between the outer layers. The core has a large number of cavities. The outer layers are bonded to the core by press molding. The first outer layer having a top surface on which a multi-layer sheet is bonded by the press molding. The sheet has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish.

Abstract: An airbag cover assembly including layered, decorative cover pieces held together at a decorative seam is provided. The assembly includes a plastic structural carrier having a tear seam and a pair of leather cover pieces overlying the outer surface of the carrier to form a covered front panel and at least one covered deployment door configured to enclose a non-inflated airbag. The tear seam forms a substantially weakened area of the carrier adjacent the at least one door. Apposed peripheral edges of the cover pieces are folded under and are adjacent one another to form the decorative seam which is adjacent to and aligned with the structurally weakened area. Stitches hold the cover pieces together at the decorative seam. The stitches burst in a controlled fashion during high-pressure impact during airbag deployment through the weakened area and through the decorative seam at the folded-under edges of the cover pieces.

Abstract: A plastic part such as an automotive vehicle interior plastic part having a dampening support surface is provided. The surface is capable of wirelessly and conductively allowing electrical signals including power signals to travel between the part and an electrical device such as a cell phone arbitrarily positioned and supported on the surface during vehicle motion.

Abstract: An assembly having a support surface capable of simultaneously supporting and wirelessly supplying electrical power to a portable electronic device supported on the support surface is provided. The assembly includes first and second members each of which is formed as a unitary molded part from at least one plastic formulated with an electrically conductive filler in a molding process. The members are assembled together so that a first set of surface portions of the first member are spaced apart and electrically isolated from a second set of surface portions of the second member to at least partially define the support surface and to allow the first and second sets of surface portions to be biased at first and second different voltage levels, respectively, at the same time to allow the wireless power transfer.

Abstract: An automotive vehicle interior plastic part having a vibration and shock damping support surface capable of wirelessly supplying electrical power to a supported electronic device during vehicle motion is provided. A part of the surface includes first and second sets of conductive, anti-vibration and anti-shock thermoplastic pads. Another part of the surface includes a non-conductive or insulating, unitary, anti-vibration and anti-shock plastic substrate bonded to the different sets of pads. The substrate electrically insulates the first set of pads from the second set of pads. A power source coupling includes first and second conductive power traces. The first trace is electrically coupled to each of the first set of pads and the second trace is electrically coupled to each of the second set of pads. The first and second traces form separate conductive pathways and are operable for biasing the different sets of pads at different voltage levels.

Abstract: A method of making a trimmed, laminated trim component is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the plastic composite sheet. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. Unwanted portions of the laminated sheet are trimmed.

Abstract: A method of making a laminated trim component at a pair of spaced first and second molding stations is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the composite sheet at the first molding station. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. The bonded sheets are transferred to the second molding station where a plastic compatible with the plastic of the composite sheet is molded around the composite sheet to form at least one component at the inner surface of the composite sheet.

Abstract: A method of making a laminated trim component is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the plastic composite sheet. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. Interior portions of the sheets stretch during the step of pressing while remaining intact.

Abstract: A carpeted, automotive vehicle, load floor including a compression-molded composite panel is provided. A cover of the load floor covers a storage area of the vehicle and is pivotally connected to the composite panel. A substantially continuous carpet layer is bonded to the top surface of the panel and the top surface of the cover to at least partially form the carpeted load floor having a carpeted cover. A living hinge allows the carpeted cover to pivot between different use positions including open and closed positions. A decorative, noise-management covering layer is bonded to the bottom surface of the cover to reduce the level of undesirable noise in a passenger compartment of the vehicle in the closed position and to provide an aesthetically pleasing appearance to the bottom of the cover in the open position.

Abstract: A method of making a sandwich-type composite panel having a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins heated to a softening temperature and a thermoplastic cellular core disposed between the skins. The first skin is stretchable when heated to the softening temperature. A pressure is applied to the stack after the step of heating to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel and a crushed portion of the panel between the two side portions. The first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge.