Abstract: A vehicle structural frame having a plurality of tubular elements is formed from first and second generally C-shaped elongated members. Each member has a first flange and a second flange separated by a web. The flanges of the first and second members overlap each other to form two pairs of overlapped flanges. Each pair of overlapped flanges of both the first and second pair of overlapped flanges are joined by at least two longitudinal welds. The longitudinal welds join each pair of flanges to form each element of the plurality of tubular elements of a vehicle structural frame. Lengthening the flange overlap and providing two or more longitudinal welds increases frame bending stiffness allowing reduced member thickness and weight.

Abstract: A fastening device has a support layer, an adhesive layer on one side of the support layer, and a removable liner on the adhesive layer opposite to the support layer, the support layer having an opening therethrough. The device facilitates securing of a catheter or like assembly to a patient. A preferred catheter assembly includes the fastening device, a needle, a cannula and a hub attached to the cannula.

Abstract: A forming device including discreet heating zones along the axial length and circumferential portion of a mold cavity. One zone can be heated to cause the heated tube portion to become more elastic than the non-heated tube portions. As a result, less axial force and radial pressures are required in order to provide the necessary metal deformation against the mold halves. Preferably, the heating zones are provided by way of a series of induction coils disposed along the axial length and circumferential portion of the tube. Each induction coil can be individually energized so that select portions of the tube are heated in a controlled manner.

Abstract: A hybrid vehicle assembly, and more particularly, a hybrid truck assembly including a hybrid passenger cab shell and a hybrid truck box are disclosed. The hybrid passenger cab shell includes a first plurality panels which are assembled together to form an inner cab shell and a second plurality of panels which are assembled together to form an outer cab shell. Generally, at least one of the first or second pluralities of panels are formed from a plastic material such as a sheet molded compound (SMC). Similarly, the truck box portion of the vehicle is formed from a plurality of inner panels which are formed from a plastic material such as SMC and are assembled together along overlapping edge portions. Thereafter, a plurality of outer panels are attached to the respective inner panels.

Abstract: A one-piece cast suspension mounting spring pocket having a circular, radially contoured disk portion and having a plurality of flanges is disclosed. The disk portion serves as a spring pocket and prevents a spring from radial movement. The flanges are parallel to and spaced from one another, and are generally perpendicular to the disk portion of the one-piece cast member. One or more of the flanges intersects a frusto-conical formation which is radially centered in the disk portion, the intersecting flange conforming to and bowing with the frusto-conical formation. The structural integrity of the one-piece cast spring pocket is improved when compared to the currently produced multi-piece spring pockets by having the flange intersect the frusto-conical section.

Abstract: A fiber reinforced plastic fuel tank includes a multipurpose inner liner that serves as an aid during molding as well as a corrosion resistant protector and/or secondary fuel container for the tank when in use.

Abstract: A vehicle door assembly including a tailored steel inner panel and an panel spaced apart by a belt-line reinforcement member. The tailored steel inner panel includes an intrusion beam which bridges first end and second ends of the inner panel.

Abstract: An intrusion beam structure for reinforcing a vehicle door includes an elongated member adapted to be attached to a surface of the inner panel of a door frame that is substantially parallel to the axis defined by the elongated member. The elongated member includes first and second end portions interdisposed by a middle portion. The end portions are substantially identical and each taper away from the middle portion. In a first embodiment, the elongated member is unitarily formed and has a substantially circular cross-section. In a second embodiment, the elongated member includes first and second bar portions which substantially traverse the entire length of the elongated member and are disposed substantially parallel to each other. The first and second bar portions are separated by an intermediate structure.

Abstract: An intrusion beam structure for reinforcing a vehicle door includes an elongated member adapted to be attached to a surface of the inner panel of a door frame that is substantially parallel to the axis defined by the elongated member. The elongated member includes first and second end portions interdisposed by a middle portion. The end portions are constructed of a first material, and the middle portion is constructed of a second, different material. The elongated member is unitarily stamped from a composite sheet and is formed to include first and second mounting members, each having a planar surface adapted to mount to the inner panel.

Abstract: A method and apparatus are disclosed for bonding a multi-panel device together by injecting a liquid adhesive into a flow channel created by a hem flange located along a perimeter of two contacting panels. The adhesive is then cured and thus forms a permanent bond between the panels.

Abstract: A fiber reinforced plastic fuel tank includes a multipurpose inner liner that serves as an aid during molding as well as a corrosion resistant protector and/or secondary fuel container for the tank when in use. This plastic fuel tank is molded by first covering an exterior surface of the inner liner with a fibrous material. The inner liner is then placed into a mold and pressurized. Thereafter, resin is injected into the mold, impregnating the fibrous material, while the inner liner supports the resin injected material to define a hollow interior for the tank. Once the resin has been injected into the mold, the resin is cured to form the molded tank.

Abstract: A molded composite bumper including a resin and reinforcing thermoplastic fibers having sufficiently compatible elongation characteristics thereby allowing the bumper to sustain higher strains and deformation upon an impact force.

Abstract: An energy absorbing structure for a vehicle door includes an elongated resin reinforced member disposed horizontally between the inner and outer panels of a vehicle door. The elongated member includes first and second enlarged ends, each having an outwardly diverging surface. The elongated member is supported at either end by first and second support members which attach to the vehicle door frame. The support members both include female receptacles having a compatible taper which allows them to mate with the respective enlarged end of the elongated member. The energy absorbing structure absorbs energy imparted laterally upon a vehicle door during side impact through deflection of the elongated member and additionally through distortion of the first and second support members.

Abstract: A method and apparatus for making fiber reinforced plastic preforms via a wet slurry process. A screen with the desired preform configuration is placed in the bottom of a tank. The tank is then filled with water and chopped fibers to create a slurry. The screen is raised up through the slurry causing fibers to be deposited on the screen in the shape of the preform. The preform is then removed from the screen, placed in a mold and injected with resin to form the desired structure.

Abstract: A hollow fiber reinforced part, especially body closures for vehicles, is made by applying preforms to a hollow, thin-walled support which has been preshaped to the general configuration of the body closure. The support is then depressurized and the support/preform subassembly placed into a mold. The mold is closed and the support again pressurized. Then, resin is injected into the mold to impregnate the fibrous pieces of the preforms. Once the resin cures, the mold is opened and the part removed.

Abstract: A method of molding in a single operation an integral fiber structure including a hollow resin impregnated fiber section. A fibrous material is placed in a mold having a hollow section formed by a first mold part and a second mold part formed by second complementary surface portions extending from the hollow first mold part. An inflatable member is placed in the mold in the cavity and inflated. Resin is injected into the fibrous material between the second complementary mold surface portions and flows toward the cavity to impregnate all of the fibrous material. The resin is cured to form a fiber reinforced structure with a sheet-like portion joined to the hollow section.

Abstract: An improved system for removing cells from bone marrow wherein the cells are bound by monoclonal antibodies conjugated to magnetic particles, the system comprising a chamber provided with inlets and outlets for flowing through the chamber a liquid sample containing the bone marrow and magnetic conjugated antibodies bound to the cells and a magnetic field source associated with the chamber wherein the improvement comprises a non-uniform magnetic field in an ascending gradient from the inlet to the outlet.

Abstract: A hollow fiber reinforced structure having irregular cross-sections, curvatures, joints and twists is provided. A method of forming the structure includes placing fibrous material on the walls of an outer mold and placing a bladder internal to the fibrous material, which serves as an inner mold. When the mold is closed and the bladder expanded, resin is injected into the fibrous material. After curing, the solid reinforced structure is formed.

Abstract: A method of making a hollow fiber reinforced plastic structure with integrally molded fastening devices for attaching external components. The fastening device is attached to a piece of fibrous material into which resin is injected. The finger holds the fastening device in place during the resin injection step. The resin is cured to form a molded structure with the fastening device lying on an outer surface thereof. After removal from the mold, the fastening device can be used to attach external components to the part.

Abstract: A method of forming a hollow reinforced fiber structure includes the steps of providing fiber reinforced material around a flexible expandable member and placing the resulting package inside of a mold which includes inner surfaces conforming to the shape of the structure being formed. A second expandable means is included in the mold on both sides of the package. After the mold is closed, pressure is applied to force the second expandable means against the fiber reinforced material. Resin is injected into the fiber reinforced material. The pressure is then decreased in the second expandable means as inflatable member is expanded to force the fiber material to conform to the inner surfaces of the mold. The fiber material is then cured to form the structure.