Abstract: A composite tie bar assembly for distributing loads to a support frame of an automotive vehicle. The tie bar assembly includes a pair of spaced apart. reinforcement bars extending longitudinally between opposing ends. A tie bar shell is supported by the reinforcement bars and extends between opposite first and second distal cods. The tie bar shell has a first support plate extending between the reinforcement bars adjacent the first distal end and a second support plate extending between the reinforcement bars adjacent the second distal end. Bach of the support plates includes a plurality of structural ribs formed Integral therewith for distributing loads from the reinforcement bars to the support frame of the vehicle.

Abstract: A composite tie bar assembly for distributing loads to a support frame of an automotive vehicle. The tie bar assembly includes a pair of spaced apart. reinforcement bars extending longitudinally between opposing ends. A tie bar shell is supported by the reinforcement bars and extends between opposite first and second distal cods. The tie bar shell has a first support plate extending between the reinforcement bars adjacent the first distal end and a second support plate extending between the reinforcement bars adjacent the second distal end. Bach of the support plates includes a plurality of structural ribs formed Integral therewith for distributing loads from the reinforcement bars to the support frame of the vehicle.

Abstract: A modified compression moulding arrangement where the compression moulding tool has been modified to allow for the use of pre-impregnated pre-form sheets in order to produce class A automotive structural parts in high volume. The pre-impregnated pre-form has continuous un-chopped fibers that extend across an entire length of the pre-impregnated pre-form. The pre-impregnated pre-form is then placed in an open compression moulding tool that has a bottom half and a top half that are movable between an open position and a closed position. When the mould tool is in the closed position, the top half and bottom half create a forming cavity that is defined by a forming surface of the top half and a forming surface of the bottom half. The forming surface of the bottom half has a boundary defined by a run-off edge and an upshear that is necessary for forming a class A structural automotive component using pre-impregnated pre-form material.

Abstract: A modified compression moulding arrangement where the compression moulding tool has been modified to allow for the use of pre-impregnated pre-form sheets in order to produce class A automotive structural parts in high volume. The pre-impregnated pre-form has continuous un-chopped fibers that extend across an entire length of the pre-impregnated pre-form. The pre-impregnated pre-form is then placed in an open compression moulding tool that has a bottom half and a top half that are movable between an open position and a closed position. When the mould tool is in the closed position, the top half and bottom half create a forming cavity that is defined by a forming surface of the top half and a forming surface of the bottom half. The forming surface of the bottom half has a boundary defined by a run-off edge and an upshear that is necessary for forming a class A structural automotive component using pre-impregnated pre-form material.

Abstract: A component made of at least one thermoformable material, having a first layer made of a first material, a second layer made of a second material, and a third layer made of the first material. The three layers form a sheet, which is formed to various shapes, depending upon the part that is to be created. The sheet may be formed to produce the bumper of an automobile, a door panel for an automobile, a flotation device, such as a pontoon for a pontoon boat, or the like. The first and third layers are SMC, and the second layer, or “core,” is disposed between the first and third layers, allowing the strength of the first and third layers to be used more efficiently, compared to a sheet having only the first and third layers, and no core.

Abstract: The present invention provides load-bearing composite panels made by surrounding with a long fiber reinforced polyurethane an assembly containing one or more load-bearing members and a structural polyurethane sandwich composite. The inventive load-bearing composite panels may help provide stronger, lighter weight structural items such as vehicle floor panels, walls for mobile homes, roof modules, truck beds, truck trailer floors and the like.

Abstract: A molded composite panel for a vehicle and a method of constructing a panel assembly. The individual panels have laminated layers of abutting dissimilar materials including a core of material and outer layers of fibrous material molded on opposite sides of the core. The outer layers are molded at least in part about a plurality of connection features such that the connection features are carried by at least one of the outer layers or the core. The connection features of one panel are accessible for operable attachment to connection features of an adjacent panel to form a panel assembly.

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 removable, bag-like protective liner is provided for the interior of a motor vehicle with a rear opening. The liner defines an internal compartment for storage of cargo in the rear of the vehicle while protecting the interior of the vehicle from damage by the cargo. The liner is supported by a plurality of attachments which secure the liner to the interior of the motor vehicle. In addition, a sidewall portion and the forward end portion are configured such that the height of the liner can be selectively adjusted based upon the interior height of the vehicle.

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.