Abstract: A technique for providing localized stiffening of a vehicle trim panel, especially for high curvature areas. The vehicle trim panel includes an outer panel having an outer show surface and an inner surface. A plurality of discrete reinforcement elements are bonded to the inner surface of the outer panel at locations where localized stiffening is desired. The discrete elements can come in a variety of different shapes and sizes, where the combination of elements and the number of elements is selected for a particular trim panel stiffness.

Abstract: A mold comprising a scaffolding support structure including a base member, a top member and side members defining an enclosure. The scaffolding structure further includes a plurality of interconnected and elongated support members interspersed within the enclosure between the base member and the top member so as to define open space within the enclosure for ease of heating and cooling fluid flow, and a plurality of flow partitions within the enclosure. An intermediate layer is formed on the top member and a working surface layer is formed on the intermediate layer.

Abstract: A number of variations may include a product that may include a substrate that may include an aluminum alloy and at least one surface and a coating that may include a metallic material deposited over the at least one surface via laser cladding.

Abstract: An injection mold assembly for injection molding an object includes a first mold tool having a first tool surface and a second mold tool having a second tool surface. The first and the second tool surfaces are cooperatively configured to define a mold cavity between the tool surfaces for an injection molding of an object. The first mold tool has a tool element with a first side that has the first tool surface, and with a second side opposite the first side. Multiple fins extend from the second side of the tool element. A base supports the fins. The tool element, the fins and the base define a coolant flow cavity at the second side of the tool element. A method of designing the mold assembly is also disclosed.

Abstract: A number of variations may include a product that may include a substrate that may include an aluminum-nickel alloy and at least one surface and a coating that may include a metallic material deposited over the at least one surface via laser cladding.

Abstract: A technique for providing localized stiffening of a vehicle trim panel, especially for high curvature areas. The vehicle trim panel includes an outer panel having an outer show surface and an inner surface. A plurality of discrete reinforcement elements are bonded to the inner surface of the outer panel at locations where localized stiffening is desired. The discrete elements can come in a variety of different shapes and sizes, where the combination of elements and the number of elements is selected for a particular trim panel stiffness.

Abstract: A method for providing localized stiffening of a vehicle trim panel using a plurality of discrete stiffening elements. The method includes selectively placing one or more of the discrete stiffening elements on the panel and then bonding the stiffening elements to the panel.

Abstract: A panel assembly including a panel having an outer show surface and an inner surface and at least one micro-truss reinforcement patch secured to the inner surface of the panel. The micro-truss patch includes a micro-truss structure having cured and interconnected.

Abstract: A process for reinforcing a trim panel for a vehicle using one or more micro-truss reinforcement patches. Each micro-truss reinforcement patch is secured to an inner surface of a show surface panel of the trim panel while it is in a partially cured state and then fully cured. The micro-truss patch is fusion bonded to the panel.

Abstract: An injection mold assembly for injection molding an object includes a first mold tool having a first tool surface and a second mold tool having a second tool surface. The first and the second tool surfaces are cooperatively configured to define a mold cavity between the tool surfaces for an injection molding of an object. The first mold tool has a tool element with a first side that has the first tool surface, and with a second side opposite the first side. Multiple fins extend from the second side of the tool element. A base supports the fins. The tool element, the fins and the base define a coolant flow cavity at the second side of the tool element. A method of designing the mold assembly is also disclosed.

Abstract: An injection mold assembly for injection molding an object includes a first mold tool having a first tool surface and a second mold tool having a second tool surface. The first and the second tool surfaces are cooperatively configured to define a mold cavity between the tool surfaces for an injection molding of an object. The first mold tool has a tool element with a first side that has the first tool surface, and with a second side opposite the first side. Multiple fins extend from the second side of the tool element. A base supports the fins. The tool element, the fins and the base define a coolant flow cavity at the second side of the tool element. A method of designing the mold assembly is also disclosed.

Abstract: In accordance with an exemplary embodiment, a method for manufacturing a tool comprises applying at least one ferro-magnetic material to at least a portion of a tool face of a different material. The method produces a tool face with varying magnetic properties facilitating substantially uniform induction heating of the tool face.

Abstract: An injection molding tool includes a first mold die having a first tool face and a second mold die having a second tool face. The second mold die is configured to abut the first mold die, wherein the first tool face and second tool face are configured to partially define a part cavity between the first mold die and the second mold die. An induction heating element is embedded into the first mold die such that the induction heating element defines a portion of the first tool face. The induction heating element includes an electrical conductor, an electrically insulating material disposed about the conductor, and a ferromagnetic material disposed adjacent the electrical conductor and electrically insulating material.

Abstract: A method of forming a weld joint includes removing a portion of an insulator from a first core of a first magnet wire and a second core of a second magnet wire so that the first wire has a first heat affectable zone and a first insulator portion adjacent the first zone, and the second wire has a second heat affectable zone and a second insulator portion adjacent the second zone. The first and second insulator portions include the insulator disposed on the first and second cores, respectively. The first and second zones have a first and second distal end spaced apart from the first and second insulator portions, respectively. The method includes welding together only the first end and the second end to form the weld joint, wherein welding does not transfer heat to the first and second insulator portions sufficient to burn the insulator.

Abstract: An injection molding tool includes a first mold die having a first tool face and a second mold die having a second tool face. The second mold die is configured to abut the first mold die, wherein the first tool face and second tool face are configured to partially define a part cavity between the first mold die and the second mold die. An induction heating element is embedded into the first mold die such that the induction heating element defines a portion of the first tool face. The induction heating element includes an electrical conductor, an electrically insulating material disposed about the conductor, and a ferromagnetic material disposed adjacent the electrical conductor and electrically insulating material.

Abstract: An injection molding tool includes a first mold die having a first tool face and a second mold die having a second tool face. The second mold die is configured to abut the first mold die, wherein the first tool face and second tool face are configured to partially define a part cavity between the first mold die and the second mold die. An induction heating element is embedded into the first mold die such that the induction heating element defines a portion of the first tool face. The induction heating element includes an electrical conductor, an electrically insulating material disposed about the conductor, and a ferromagnetic material disposed adjacent the electrical conductor and electrically insulating material.

Abstract: A method of forming a weld joint includes removing a portion of an insulator from a first core of a first magnet wire and a second core of a second magnet wire so that the first wire has a first heat affectable zone and a first insulator portion adjacent the first zone, and the second wire has a second heat affectable zone and a second insulator portion adjacent the second zone. The first and second insulator portions include the insulator disposed on the first and second cores, respectively. The first and second zones have a first and second distal end spaced apart from the first and second insulator portions, respectively. The method includes welding together only the first end and the second end to form the weld joint, wherein welding does not transfer heat to the first and second insulator portions sufficient to burn the insulator.

Abstract: An injection molding tool includes a first mold die having a first tool face and a second mold die having a second tool face. The second mold die is configured to abut the first mold die, wherein the first tool face and second tool face are configured to partially define a part cavity between the first mold die and the second mold die. An induction heating element is embedded into the first mold die such that the induction heating element defines a portion of the first tool face. The induction heating element includes an electrical conductor, an electrically insulating material disposed about the conductor, and a ferromagnetic material disposed adjacent the electrical conductor and electrically insulating material.

Abstract: In accordance with an exemplary embodiment, a method for manufacturing a tool comprises applying at least one ferro-magnetic material to at least a portion of a tool face of a different material. The method produces a tool face with varying magnetic properties facilitating substantially uniform induction heating of the tool face.

Abstract: A ditch molding has a head with left and right wings that lap onto the roof, a stem depending from the head, and an enlarged foot at the lower end of the stem. A molding clip has a base mounted in the ditch and left and right biasing arms have wedge faces that engage with the foot to urge the foot downwardly into the ditch, establishing an installed position of the molding. The left and right biasing arms yield away from each other upon an upward movement of the foot. Left and right trap arms also provided on the clip have trap ends overlying the foot of the molding in spaced relation there from when the molding is in the installed position. Upward movement of the foot causes the foot to engage with the trap ends of the trap arms, trapping the foot against further upward movement.