Abstract: A tailgate system for a vehicle comprises a tailgate and a support system. The tailgate includes a movable tailgate portion movably connected to the tailgate and configured to cover an access opening in the tailgate. The support system is selectively operable between a connected state connected to both the tailgate and the movable tailgate portion and a disconnected state. The support system in the connected state is configured to support the movable tailgate portion in a step position pivoted downwardly from the tailgate in an open position thereof to provide a step. The support system in the disconnected state is configured to allow the movable tailgate portion to pivot downwardly from the tailgate in a closed position to the downwardly extending open position. The angle of pivotal movement of the movable tailgate portion relative to the tailgate is greater in the downwardly extending open position than in the step position.

Abstract: A tailgate system for a vehicle comprises a tailgate and a support system. The tailgate includes a movable tailgate portion movably connected to the tailgate and configured to cover an access opening in the tailgate. The support system is selectively operable between a connected state connected to both the tailgate and the movable tailgate portion and a disconnected state. The support system in the connected state is configured to support the movable tailgate portion in a step position pivoted downwardly from the tailgate in an open position thereof to provide a step. The support system in the disconnected state is configured to allow the movable tailgate portion to pivot downwardly from the tailgate in a closed position to the downwardly extending open position. The angle of pivotal movement of the movable tailgate portion relative to the tailgate is greater in the downwardly extending open position than in the step position.

Abstract: A plastic panel suitable for use in an automotive vehicle or other structure is provided wherein the plastic panel includes a polycarbonate substrate, a PMMA layer and a scratch resistant coating. The polycarbonate substrate may have a thickness approximately between 2.0 mm and approximately 6.0 mm. The PMMA layer may be disposed onto the polycarbonate substrate and the PMMA layer may have a thickness approximately between 0.25 mm and approximately 3.0 mm. The scratch resistant coating is applied to both the PMMA layer and the PC substrate.

Abstract: A vehicle air dam assembly is provided which includes a motor, a drive linkage and an active air dam which can be deployed or stowed on a vehicle. The motor is mounted to a vehicle bumper. The drive linkage is coupled to the motor and is affixed to the vehicle bumper. The drive linkage includes a drive member and a biasing means. The active air dam may be coupled to the drive linkage via a four bar linkage.

Abstract: A vehicle air dam assembly is provided which includes a motor, a drive linkage and an active air dam which can be deployed or stowed on a vehicle. The motor is mounted to a vehicle bumper. The drive linkage is coupled to the motor and is affixed to the vehicle bumper. The drive linkage includes a drive member and a biasing means. The active air dam may be coupled to the drive linkage via a four bar linkage.

Abstract: A plastic panel suitable for use in an automotive vehicle or other structure is provided wherein the plastic panel includes a polycarbonate substrate, a PMMA layer and a scratch resistant coating. The polycarbonate substrate may have a thickness approximately between 2.0 mm and approximately 6.0 mm. The PMMA layer may be disposed onto the polycarbonate substrate and the PMMA layer may have a thickness approximately between 0.25 mm and approximately 3.0 mm. The scratch resistant coating is applied to both the PMMA layer and the PC substrate.

Abstract: An air dam is provided which includes an upper portion, an intermediate portion and a flexible lower portion. The upper portion is affixed to the underside of a vehicle. The intermediate portion is integral to the upper portion. The flexible lower portion is affixed to the upper portion. The intermediate portion of the air dam is operatively configured to structurally support the flexible intermediate portion.

Abstract: An air dam is provided which includes an upper portion, an intermediate portion and a flexible lower portion. The upper portion is affixed to the underside of a vehicle. The intermediate portion is integral to the upper portion. The flexible lower portion is affixed to the upper portion. The intermediate portion of the air dam is operatively configured to structurally support the flexible intermediate portion.

Abstract: A vehicle bumper assembly includes a polymeric support structure and a metal cover. The polymeric support structure may be one piece or a multi-piece component. The polymeric support structure includes a plurality of ribs formed on a substantially vertical wall. The chrome-plated metal cover is disposed on the one-piece polymeric support structure.

Abstract: Disclosed is a unitary face shield for a sports helmet. The shield includes a first portion which is comprised of a transparent polymeric material and a second portion comprised of a structural polymeric material. The second portion has a plurality of openings defined therethrough, and the first and second portions are fusion bonded together in an edge-to-edge relationship so as to produce a unitary body. The face shield may include still further portions and these may be structural or transparent portions. The transparent portions are fabricated from a high-impact material such as polycarbonate or impact-modified acrylic, and the structural portions are fabricated from high strength structural polymers such as nylon, polypropylene, polycarbonate, ASA, and various combinations. The structural polymer may include reinforcing materials. Also disclosed are methods for manufacturing the shield by composite molding processes.

Abstract: A unitary cowl top ventilator component has a body of rigid, polymeric material which defines a structural member of the component. A first body of polymeric material is fusion bonded to a first portion of the structural member to provide a windshield seal, and a second body of polymeric material is fusion bonded to a second portion of the structural member to provide a hood seal. In some instances the hood seal is a bulb-type seal, and in other instances it is a blade seal.

Abstract: Disclosed is a unitary cowl top ventilation component for a motor vehicle. The component includes structural and elastomeric portions molded into a single unitary body. Also disclosed are methods for making the component.

Abstract: Disclosed is a unitary cowl top ventilation component for a motor vehicle. The component includes structural and elastomeric portions molded into a single unitary body. Also disclosed are methods for malting the component.

Abstract: A fan shroud ring comprises a first member formed from a polymeric material and configured to be affixed to an internal combustion engine. The first member defines a central opening configured to have a fan associated with the engine project therethrough. The shroud ring includes a second member fabricated from an elastomeric material. The second member is bonded to the first member and encompasses at least a portion of the periphery of the first member. The elastomeric material may include a number of notches formed along its circumference. The notches allow for the flexing of the elastomeric material and thereby enhance the seal between the shroud ring and other components of a cooling system. The shroud ring may include integral stator blades for directing airflow and may also include mounting blocks and associated hardware. The fan shroud ring may be fabricated by an injection molding process.

Abstract: Disclosed is a unitary face shield for a sports helmet. The shield includes a first portion which is comprised of a transparent polymeric material and a second portion comprised of a structural polymeric material. The second portion has a plurality of openings defined therethrough, and the first and second portions are fusion bonded together in an edge-to-edge relationship so as to produce a unitary body. The face shield may include still further portions and these may be structural or transparent portions. The transparent portions are fabricated from a high-impact material such as polycarbonate or impact-modified acrylic, and the structural portions are fabricated from high strength structural polymers such as nylon, polypropylene, polycarbonate, ASA, and various combinations. The structural polymer may include reinforcing materials. Also disclosed are methods for manufacturing the shield by composite molding processes.

Abstract: A passive pool skimmer has a T-shaped buoyant stabilizer end and a flexible strap which provides a readily displaceable structure that removes debris from the surface of a pool. The pool skimmer includes a rectangular frame having a net attached thereto in the configuration of a rectangular pouch. At one end of the frame, two floats are attached to the ends of a T-shaped structure. The floats rest against the side of the pool and, in combination with a float at the opposite end of the frame, provides sufficient buoyancy to substantially center the opening of the frame at the water level. A flexible strap with a quick disconnect is attached to the skimmer and allows relative motion of the pool skimmer.

Abstract: A staged coinjection molding process to produce a vehicular mud guard or similar molded article having regions of different mechanical properties. The process includes the steps of injecting a relatively small quantity of low flexural modulus (flexible) plastic resin to form a skin along the proximal walls of the mold cavity, followed by an injection of high flexural modulus (stiff) plastic resin. Finally, a second injection of flexible resin is introduced into the mold to force to stiff material to the distal region of the mold. This results in the two dissimilar plastic materials having a longitudinal interface to reduce the risk of delamination.

Abstract: A ceiling has elongated suspension members that attach to ceiling joists or structure and an interlocking tile mechanism. The individual tiles are provided with opposed side walls having mating interlock features for aligning and supporting a network of suspended tiles.

Abstract: A trackless drop ceiling has elongated suspension members that attach to ceiling joists or structure and an interlocking tile mechanism. The individual tiles are provided with opposed side walls having mating interlock features for aligning and supporting a network of suspended tiles.