Abstract: A thermoplastic liftgate inner panel construction is provided by using a co-injected injection molding process. In a first phase, a class A surface material is injected into the molds and thereafter in a second phase an inner core of material is injected using a gas-infused reinforced polymer.

Abstract: A modular gate combined with multiple functions which can be easily employed with existing tailgates without any hardware or mounting modifications to existing truck beds. There is provided a modular tailgate system having a tailgate portion in combination with a plurality of functions. The modular tailgate system integrates any combinations of at least two of the plurality of features without affecting existing body sides and/or existing truck beds. Integrated features include a multi-functional gate (e.g., swing, drop, etc), storage (e.g., normal, sealed, refrigerated, heated, etc), step(s), lighting (e.g., ingress/egress, bed interior, removable, trailer hitch, parking, etc), bed extension(s), power (e.g., 12v and/or 110v), tie downs (e.g., ratchets, anchors, etc), sawhorse, magnet(s), table(s), bench(es), seat(s), net(s), any other predetermined desired function, etc., and combinations thereof.

Abstract: A molded vehicle component (10) having a skin (14) and a lower density core (16) formed by a co-injection molding process. In a first phase, a first material for forming the skin of class A surface material is injected into a mold to partially fill the mold cavity (104). Thereafter, in a second phase, a second material is injected into the same cavity (104) to complete filling of the mold cavity (104). The second material can flow only to portions of the part where the first material is still molten and displaces the molten core of the first phase, pushing it away from co-injection gates until the mold cavity is full. The second material is pre-treated with a chemical blowing agent in order to reduce part weight by foaming the core material. The finished co-injection molded part (10) has one material on all visible class A surfaces (14) and a core (16) that is a different, less dense material.

Abstract: A thermoplastic liftgate inner panel construction is provided by using a co-injected injection molding process. In a first phase, a class A surface material is injected into the molds and thereafter in a second phase an inner core of material is injected using a gas-infused reinforced polymer.

Abstract: A bumper (10) created using a resistive implant welding process. The bumper includes a mounting plate portion (12) and a composite bumper portion (14). The mounting plate portion (12) is connected to the composite bumper portion (14) using a resistive implant welding process. In one embodiment, the present invention includes a bumper for a vehicle having a mounting plate (12) and a bumper portion (14). The bumper portion (14) includes at least one flange (24) formed as part of the bumper portion (14), a first contact area (28) formed as part of the mounting plate (12), and a second contact area (30) formed as part of the flange (24). A connection point is used to bond the first contact area (28) and the second contact area (30) such that the mounting plate (12) is connected to the bumper portion (14).

Abstract: A bumper (10) created using a resistive implant welding process. The bumper includes a mounting plate portion (12) and a composite bumper portion (14). The mounting plate portion (12) is connected to the composite bumper portion (14) using a resistive implant welding process. In one embodiment, the present invention includes a bumper for a vehicle having a mounting plate (12) and a bumper portion (14). The bumper portion (14) includes at least one flange (24) formed as part of the bumper portion (14), a first contact area (28) formed as part of the mounting plate (12), and a second contact area (30) formed as part of the flange (24). A connection point is used to bond the first contact area (28) and the second contact area (30) such that the mounting plate (12) is connected to the bumper portion (14).

Abstract: A method for powder coating plastic substrate. The substrate in one embodiment is a formed part for a vehicle made from a polypropylene base, polyolefins or acrylonitrile butadiene styrene. The method also further involves providing a conductive adhesion promoter, such as a chlorinated polyolefin that includes a conductive carbon black filler. A powder coat material is applied at a later step and then is melted onto the substrate creating a finished part having a high quality finish.

Abstract: A plasma spray process used for coating surfaces of a variety of components made of a plastic substrate. Powder particles are injected into a plasma jet where they soften and then strike the surface at high velocity to produce a strongly adherent coating. The component or work piece the coating is being applied to remains cool because the plasma is localized at the plasma gun. The plasma spray process allows for the melting of glass particles, creating a transfer mechanism to the plastic substrate. Components having complex shapes can be coated, without the issues currently encountered in dip coating. The powder coating is applied via plasma spraying, as a protective layer, giving glass like surface properties to a component having complex molded or formed shapes.

Abstract: An automotive bumper assembly preferably includes a resilient attachment strip secured to the bumper assembly's inner structural bumper member. The attachment strip includes resilient fingers with preferably hook-shaped edge portions that mate and interlock with preferably hook-shaped edge portions of an outer decorative fascia member. This configuration allows the fascia member to be conveniently snapped into place on the structural inner bumper member with only minimal clearance being needed for a secure attachment.

Abstract: One embodiment is a bumper fascia support for supporting a motor vehicle bumper fascia wherein the bumper fascia generally has a C-shaped transverse cross-section with an upper skirt and a lower skirt. The bumper fascia support has a front side and a back side relative to its position on the motor vehicle and comprises an elongated platform and at least one base member connected to the elongated platform. The platform is adapted to be attached to the upper skirt of the C-shaped bumper fascia and has an upper surface and a lower surface, the upper surface being adapted for supporting the upper skirt of the C-shaped bumper fascia. The base member is adapted to be attached to the lower skirt of the C-shaped bumper fascia. A second embodiment is a bumper fascia support and reinforcement assembly for supporting and reinforcing a motor vehicle bumper fascia.