Abstract: Composite doors are described which include a frame defining at least two openings and at least two composite panels situated within the openings in the frame. Preferred uses for such composite doors are as plug doors for use on railcars.

Abstract: A method of fabricating composite vehicle panels includes the steps of forming a first, upper panel having a depending peripheral lip, forming a second, lower panel of laid up woven mat or strips of a fibrous material such as fiberglass or carbon fibers and a plastic resin to form a corrugated panel having a depending peripheral lip, placing an adhesive on the raised portions of the corrugations and the peripheral lip of the second panel and securing the panels together at the corrugations and about their peripheral lips.

Abstract: Described herein is a process for manufacturing a part or a part pre-form, for example, a vehicle part or vehicle part pre-form, as well as articles of manufacture incorporating pre-stretched paint films and substrates such as extruded sheet. Also described herein is an apparatus useful for the process described, which process includes providing a paint film having a length as measured along a longitudinal axis of the paint film; continuously stretching the paint film in the transverse and/or longitudinal directions of the film over the length of the paint film to form a pre-stretched paint film; and applying the pre-stretched paint film to a thermoformable substrate to form a part or part pre-form.

Abstract: A motor vehicle bed or bed liner is vacuum formed from a single layer or two layer panel of thermoplastic material having a scuffed or roughened surface. The single layer panel is typically extruded and is homogeneous, being either a single material such as HDPE or a uniform mixture of materials. The two layer panel is co-formed of two layers of material which will typically be distinct compositions and characteristics. The upper surface of the panel is scuffed or roughened by a brush which contacts the surface. A bank of individually adjustable rollers supports the panel during the roughening operation and facilitates adjustment of the extent of contact or impingement of the brush on the surface of the panel at a plurality of transverse locations across the panel. The roughened panel is then vacuum formed into, for example, a truck bed or bed or cargo compartment liner.

Abstract: A method of manufacturing a laminated pickup truck bed and bed liner includes the steps of forming by extrusion or another process a substrate layer of a desired thickness and strength of a thermoplastic material such as high-density polyethylene (HDPE) which may include fibers or a fibrous mat which improves its strength and ruggedness. Also formed by extrusion or another process is an upper layer having specific characteristics such as electrical charge dissipation or improved skid or slip resistance. The upper layer may be fabricated of a thermoplastic material such as HDPE and includes dispersed conductive material such as carbon particles, carbon, fibers or conductive polymers which dissipate or carry static electrical charges to a vehicle ground. Skid or slip resistance may be achieved by controlling the upper layer surface texture or the use of various materials and mixtures.

Abstract: A method of fabricating composite vehicle panels includes the steps of forming a first, lower panel with a plurality of raised features having coplanar end portions, forming a second, upper panel having a depending peripheral lip adapted to engage a periphery of the first panel, placing an adhesive on the end portions of the raised features of the first panel and securing said panels together at the raised features and about the peripheral lip.

Abstract: A method of fabricating composite vehicle panels includes the steps of forming a first, upper panel having a depending peripheral lip, forming a second, lower panel of laid up woven mat or strips of a fibrous material such as fiberglass or carbon fibers and a plastic resin to form a corrugated panel having a depending peripheral lip, placing an adhesive on the raised portions of the corrugations and the peripheral lip of the second panel and securing the panels together at the corrugations and about their peripheral lips.

Abstract: A running board for a passenger car or light truck is assembled from an upper molded thermoplastic section or component having a Class A automotive finish and a lower component or section having reinforcing ribs and mounting brackets. The upper section includes three layers: a paint film having a Class A automotive finish, a thin layer of thermoplastic polyolefin (TPO) and a thick layer of polypropylene. The lower section is homogeneous and may be a plastic such as TPO, polypropylene or high-density polyethylene (HDPE), for example, which may contain chopped, randomly oriented glass reinforcing fibers. The two sections are secured to one another about their peripheries by autogenous bonding.

Abstract: Apparatus for forming wide paint film parts includes a frame; and, attached to the frame, at least two paint film stock grasping members, which generally oppose one another, which can grasp deformable paint film stock, at least one of which can be moved apart from the other while the stock is grasped. The frame may have lateral support members in a rectangular or square arrangement, and the grasping members may include orthogonal, oblique and corner types. The apparatus can be electrically controlled and/or pneumatically actuated. Wide paint film parts may be formed by providing the apparatus; providing a deformable paint film stock; grasping the stock on generally opposing sides by at least two paint film stock grasping members; and, moving, while the stock is so grasped, the at least one of the two paint film stock grasping members apart from the other so as to draw or stretch the stock. A drawn or stretched paint film stock part precursor or a formed wide paint film stock part can result.

Abstract: A composite material includes five distinct layers of material: two thin outer layers or panels, a central rigid core and intermediate foam layers on both sides of the core which fill the regions between the core and outer panels. The core can be a wide variety of material but is preferably a rigid foam or wood having resin or epoxy impregnated fiber or fiber filled outer skins. An array of apertures extends through the core. During the fabrication process, the apertures facilitate cross flow of the foam and ensure even distribution thereof. As a finished product, the foam filled apertures ensure positive location and retention of the core within the foam. The foam may be any suitable injectable foam but is preferably a composition which remains resilient upon curing as such foam more readily accommodates dimensional changes between the layers due to, for example, ambient temperatures changes.

Abstract: A cargo van bulkhead provides a barrier between the driver and passenger of a van and the cargo compartment. The bulkhead comprises a molded, complexly curved unitary panel which fits snugly against the bottom, sidewalls and top of the van behind the driver's and passenger's seats. The bulkhead includes a plurality of horizontal convolutions which define alternate ribs or projections and recesses which greatly improve the rigidity and strength of the bulkhead. An irregular flange disposed about the periphery of the bulkhead is configured to mimic the interior profile of the van and thus facilitate installation and securement thereto. An optional opening in the upper central portion of the bulkhead may receive a window which facilitates inspection of the cargo within the van as well as a view out the rear of the van if the rear doors of the van are equipped with windows.

Abstract: An insurance estimation, service manual or other system stores and displays documents and associated graphics. The system stores a multiplicity of the graphic images in compressed, digital form. A first group of the graphic images are associated with a first one of the documents. By selecting the first document, the system automatically decompresses the first plurality of graphic images. The system then displays at least a portion of the selected first document on a display screen along with a first one of the decompressed graphic images. Subsequently, upon touch of a touch screen, the system displays a second one of the decompressed documents. Because the second graphic image was decompressed when the document was selected, there was virtually no delay in displaying the second graphic image. Either graphic image can be enlarged and centered about or near a point of touch over the image.