Abstract: A structural reaction injection molded motor vehicle bumper beam comprises a preform formed of layers of interlaced glass fibers and chopped glass fibers wherein most of the interlaced fibers are oriented longitudinally of the bumper beam. A two-component, non-filled reaction injection molding polymeric/pure polyurethane based resin with a neat elongation in excess of about 50% bonds the fiberglass layers together in a composite bumper beam structure wherein the fiberglass provides substantial strength and stiffness and the highly compliant resin allows extensive beam deflection without catastrophic cracking to enable the bumper beam without other assistance to absorb sufficient energy in repeated impacts to meet in-service requirements.

Abstract: A vehicle bumper system includes a structural reaction injected molded (SRIM) bumper beam that has a hollow body of generally C-shaped cross section and a SRIM reinforcement leaf that is attached to the front wall of the hollow body to increase the damage free impact resistance of the SRIM bumper beam. The reinforcement leaf can be separately molded and bonded to a front wall of the hollow body by a resilient adhesive or molded as an integral part of the hollow body. In the latter case, the integral reinforcement leaf can be solidly attached or it can be attached at the perimeter with its center separated from the front wall of the hollow body by an intervening layer of resilient material. An energy absorber pad of resilient foam material may be attached to a face of the front wall of the hollow body for increasing damage free impact resistance.

Abstract: A fiber placement control apparatus for selectively directing a stream of fiber onto a stationary preform screen, including a rigid, straight fiber delivery tube communicating from a conventional chopper/blower assembly. A first set of four circumferentially equally spaced nozzles adjacent the exit end of the tube directs a binder into the stream of fibers, and a second set of four circumferentially equally spaced nozzles positioned downstream of the first set directs air onto the stream. By selectively operating any three of the air nozzles, the direction of the stream toward the preform screen is controlled. A conventional multidirectional gantry head may serve to move the rigid delivery tube vertically, left and right, and relative to the screen.

Abstract: A mold assembly is disclosed for making a reinforcing panel structure including female and male molds with each mold having a base surface with four sided projections extending upwardly from the base surface to a raised surface. The projections of each mold are spaced from the next adjacent projection in that mold in a first direction a distance equal to the dimension of the projection in that direction plus a predetermined dimension which is double the thickness of the rib of the panel and with each projection spaced from the next adjacent projection in that mold in a second direction perpendicular to the first direction a distance equal to the dimension of the projection in that second direction plus a predetermined dimension which is double the thickness of the rib of the panel. Each of the projections have embossments thereon.