Abstract: Co-molding of non-crimped fabric and sheet molding composition. The pre-preg of non-crimped fabric is dried to achieve suitable stiffness for molding. The pre-preg allows the pre-formed non-crimped fabric feature to retain its shape during molding. A plurality of thorns is provided in the molding tooling to further prevent movement of pre-preg during molding. The method of co-molding includes, drying of the pre-preg to achieve suitable stiffness for molding, pre-forming of the pre-preg, and incorporating a plurality of stand-off features or thorns in the molding tool to prevent movement of pre-preg during co-molding so that predetermined full coverage of non-crimped fabric is maintained in predetermined area(s) of the molded part and the continuous fibers of the non-crimped fabric are not distorted.

Abstract: A novel method and set of structures for performing resistive implant welding of two plastic components to form an assembly. A first one of the components to be welded includes a channel structure which receives the resistive implant and maintains it in a desired position until the welding operation is performed. The second component to be welded includes a complementary structure including a land which is sized to engage the channel structure and captive resistive implant on the first component. The two components are pre-weld positioned with the land in the channel structure and the positioned components are then placed in a press which exerts a pre-selected pressure on the interface between the channel and the land. Next, a pre-selected electric current is passed through the resistive implant to heat it and to bring the plastic material of the channel structure and the land to their molten points, where they intermingle through the resistive implant.

Abstract: A bracket assembly including a plurality of components attached along a hem line, a plurality of attachment points along the hem line, a first bracket, and a second bracket. The first bracket connects to the plurality of components at at least one of the plurality of attachment points, and supports a longitudinal load applied to at least one of the plurality of components. The second bracket connects to the plurality of components, and supports a lateral load applied to at least one of the plurality of components.

Abstract: A bracket assembly including a plurality of components attached along a hem line, a plurality of attachment points along the hem line, a first bracket, and a second bracket. The first bracket connects to the plurality of components at least one of the plurality of attachment points, and supports a longitudinal load applied to at least one of the plurality of components. The second bracket connects to the plurality of components, and supports a lateral load applied to at least one of the plurality of components.

Abstract: The present invention relates to a composite tailgate providing a one piece structural member that has an integrated storage space. The tailgate is made of a structural member which has a skin attached to its exterior side and a hinged access panel that is attached to its interior side. A cap is used to secure the skin and hinged access panel to the structural member. The hinged access panel can be opened when the tailgate is in a flat position in order to create storage space. The size of the storage space depends on the size of the structural member. The tailgate and the components are made of composite materials in order to minimize the weight of the tailgate.

Abstract: A series of brackets is provided that have a universal base, but have unique mounting features which are used to mount a running board onto a vehicle's inner rocker panel. The running boards have a support which has a universal mounting surface that can accept the bracket's universal base in order for the bracket to attach to the support. The top of the bracket can be shaped differently in order to avoid obstructions on the vehicle's inner rocker panel. Therefore, the running board can be mounted easier because the top of the bracket can be shaped to avoid the inner rocker panel's obstructions and the bottom can be formed to the universal shape in order to fit the running board's support.

Abstract: Systems and methods are provided for compounding a thermoplastic melt for molding articles, the melt being reinforced with reinforcing fibers. The thermoplastic material is plasticized with an adhesion promoting agent to obtain an initial melt to which the reinforcing fibers are added. The thermoplastic material forms bonds to bond reception sites on the reinforcing fibers to obtain an intermediate melt to which one or more desired additives, such as a colorant, are then added to obtain the final melt. By forming the intermediate melt without the presence of the one or more desire additives, competition between the one or more desired additives and the thermoplastic material for the bond reception sites is prevented, as is damage to the reinforcing fibers from abrasives in the one or more desired additives. Articles molded with the resulting final melt have improved mechanical properties compared to articles made with prior art methods and systems.