Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: The present invention includes a flexible, resilient composite spring pivotally connected to the vehicle wheel assembly by standard means such as a ball joint and knuckle. The composite spring is formed having a sinusoidal profile with rectangular cross-section preferably spanning transversely between parallel vehicle wheel assemblies. The composite spring is pivotally connected to the parallel vehicle frames by opposing perpendicular brackets welded to an upper and lower portion of the vehicle frame. A rubber bushing is preferably provided within each bracket and is in contact with opposing sides of the composite spring, allowing the spring to pivot between the vehicle frame. The composite spring is preferably formed with carbon and glass fibers. The sinusoidal composite spring blank is preferably molded with a neutral axis extending along the length of the spring at a midpoint of the sinusoidal profile.

Abstract: A two piece fiber reinforced composite wheel includes a molded inner rim portion defining an outboard engagement surface and a molded outer rim portion defining an inboard engagement surface. The inner and outer rim portions are conformed so as to interlock together and are adhesively bonded. The inner and outer rim portions engage forming a plurality of spoke sections having substantially box shaped cross sections. The spoke sections are further connected with fasteners.

Abstract: A method and arrangement of bonding a film applique to a molded item produces a bright, textured and/or colored surface on a resin transfer molded item. The film is vacuum formed and placed into a female cavity of a mold. The film bonds to the molded item during the resin injection and solidification steps.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: The present invention includes a flexible, resilient composite spring pivotally connected to the vehicle wheel assembly by standard means such as a ball joint and knuckle. The composite spring is formed having a sinusoidal profile with rectangular cross-section preferably spanning transversely between parallel vehicle wheel assemblies. The composite spring is pivotally connected to the parallel vehicle frames by opposing perpendicular brackets welded to an upper and lower portion of the vehicle frame. A rubber bushing is preferably provided within each bracket and is in contact with opposing sides of the composite spring, allowing the spring to pivot between the vehicle frame. The composite spring is preferably formed with carbon and graphite fibers. The sinusoidal composite spring blank is preferably molded with a neutral axis extending along the length of the spring at a midpoint of the sinusoidal profile.

Abstract: A vehicle plastic body panel such as a vehicle hardtop is formed with an integral reinforcing component including a structural fiber material molded into the body panel. The reinforcing component provides internal structural support for the use of horizontal plastic body panels such as a roof or a hood panel without the panel sagging.

Abstract: An automobile bumper retention system is provided including a plastic foam energy absorbent bumper which is held firmly in place by a metal bumper beam. The beam is provided with integral ribs or beads that fit into a matching groove in the energy absorbing bumper in order to support the energy absorbing bumper in a snap-fit engagement or a slide-in engagement.

Abstract: A stiff torque box is used with frame rail segments to compose a vehicle frame. The stiff torque box is used to cross-link the left hand and right hand sides of a vehicle frame and is made up of an extruded aluminum skeleton which forms a number of internal cavities, as well as connecting tabs. The connecting tabs are used to fix the frame rail segments to the stiff torque box. Implementing stiff torque boxes in vehicle frame construction allows for more rigid vehicle frames with the advantage of additional weight savings. This construction is ideal for aluminum frame, front wheel drive and body on frame vehicles. Because of the characteristics of such a vehicle frame, opportunities arise to implement other weight conservative vehicle components.

Abstract: A vehicle suspension system is provided including a trailing arm which is adapted to be pivotally connected to a frame of the vehicle. A wheel assembly is mounted to a first end of the trailing arm and a torsion element is integrally mounted within the trailing arm. A crank arm is provided having a first end mounted to the torsion element and a second end which is substantially fixed against movement in a vertical direction. As the trailing arm moves in a vertical direction, the crank arm provides torsion to the torsion element which acts as a spring for the vehicle suspension. By substantially mounting the entire suspension system directly below the vehicle frame rails, increased space is available between the wheels for luggage, fuel and spare tire storage. The rear suspension package is substantially reduced in both size and weight.

Abstract: A protective liner is provided for vehicles having a rear hatch or opening doors. The protective liner attaches to the opening of the rear hatch or opening and extends into the rear vehicle cavity protecting the vehicle interior form damage and debris when the vehicle is used for hauling lumber, logs, sand, gravel or debris.

Abstract: An apparatus for mounting components to a motor vehicle including a frame having a bonding face and a nut coupled to the frame where the nut has a mounting face protruding a distance from the bonding face. The apparatus further includes a plastic body panel having an inner face and an outer face defining a thickness substantially equivalent to the protrusion distance of the nut. The plastic panel further has an aperture extending through its thickness. The nut is disposed in the aperture. The inner face is coupled to the bonding face and the outer face is substantially co-planar to the mounting face. A vehicle component is secured to the frame by a threaded fastener which engages the nut. The vehicle component abuts directly against the mounting face of the nut so that little or no clamping forces are applied to the plastic body panel.