Abstract: A liftgate structure having a composite inner panel with an outside surface having a lower perimeter surface area extending across the entire width of the composite liftgate structure. Connectable to the inner panel is a composite outer panel that has an inside surface with a lower perimeter surface area extending across substantially the entire width of the liftgate structure. Between the inner panel in the outer panel is a backing curtain. The backing curtain is connected to the outside surface of the inner panel such that the backing curtain is positioned between the outer panel on the inner panel and extends substantially across both the lower perimeter surface area of the inner panel and the lower perimeter surface area of the outer panel. The backing curtain prevents broken pieces of the outer panel for moving past the backing curtain in the event of an impact on the liftgate structure.

Abstract: An independent add-on automated vehicle lift gate system utilizing existing key fob authentication circuits in combination with an independent voice control system. The system uses microphones in connection with audio acquisition hardware and voice recognition hardware that actively listen for one or more voiced commands from a user outside of a vehicle. Before activating the mechanical system, which is for example the actuator of the lift gate and lock mechanism for the lift gate, the system will wait for confirmation from a separate vehicle system that monitors and notifies the vehicle lift gate system when an identification code is received from a key fob transponder located in a predetermined proximity of the vehicle, thereby authenticating the one or more voiced commands detected by the microphones.

Abstract: Reinforced composite structural members and methods of forming thereof. The method includes providing one or more reinforcements, one or more adhesives, a mold with a mold cavity and resin. The one or more reinforcements are coated with the one or more adhesives and then are placed within the mold cavity. Next the mold cavity is closed and a step of overmolding the one or more reinforcements by injecting molten resin into the mold cavity, then curing the molten resin to form the structural member. The one or more adhesives coated onto the one or more reinforcements facilitates the bonding of the resin of material to the one or more reinforcements.

Abstract: A method of resistive implant welding carbon fiber thermoplastic composites which includes providing at least two portions of a component formed with carbon fiber material, the at least two portions of the component each have a welding surface where the at least two portions of the component are welded together. One or more conductors of copper or aluminum mesh material positioned between the welding surface of the two portions. The method includes a forming tool having at least two portions capable of moving between an open position and a closed position. The forming tool has a welding region with non-conductive metal surface areas where electric current is selectively applied to facilitate the welding together of the at least two portions of the component. The forming tool has forming regions with conductive surfaces where the two components are shaped.

Abstract: A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

Abstract: A method of resistive implant welding carbon fiber thermoplastic composites which includes providing at least two portions of a component formed with carbon fiber material, the at least two portions of the component each have a welding surface where the at least two portions of the component are welded together. One or more conductors of copper or aluminum mesh material positioned between the welding surface of the two portions. The method includes a forming tool having at least two portions capable of moving between an open position and a closed position. The forming tool has a welding region with non-conductive metal surface areas where electric current is selectively applied to facilitate the welding together of the at least two portions of the component. The forming tool has forming regions with conductive surfaces where the two components are shaped.

Abstract: A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

Abstract: A shipping pallet having a top deck, a bottom skid, and a plurality of posts disposed between and separating the top deck and the bottom skid such that at least one tow fork is able to be positioned between the top deck and the bottom skid. The shipping pallet also includes a plurality of collars formed as part of the top deck, and the posts are integrally formed as part of the bottom skid. Each of the plurality of posts is received into and connected to a respective one of the plurality of collars. There is also a plurality of reinforcements, and each of the reinforcements is disposed within and surrounded by a post. Each post and reinforcement is received into one of the collars, and the post is connected to the collar through a connection point, such as an adhesive joint or thermoplastic weld.

Abstract: A pallet used for stowing and transporting items for shipping. The pallet design of the present invention includes a top deck, a bottom skid, and several posts for providing support between the top deck and bottom skid. The posts are integrated with either the top deck or bottom skid. Within each pallet post is a steel tube reinforcement that is overmolded directly into the bottom skid, or is assembled after the pallet post is molded. The supports, which are typically hollow posts, are molded onto either the top deck or bottom skid, and a thermoplastic weld or adhesive joint is applied to the posts to complete the assembly. The palled having the integrated posts and reinforcements provides an economical approach of reinforcing pallet posts to absorb tow fork impact.

Abstract: A method of forming members of fiber reinforced thermoplastic members via molding, the members including at least one hollow chamber, formed by water injection into the melt in the mold, to stiffen the finished member. The thermoplastic is preferably selected from a group comprising polypropylene, Nylon, PET, ABS, TPO, and thermoplastic polyurethane, while the reinforcing fibers are preferably selected from a group comprising glass, aramid, carbon, and natural fibers. Preferably, the extruded melt is produced such that the average length of the reinforcing fibers is less than four millimeters.

Abstract: A pallet used for stowing and transporting items for shipping. The pallet design of the present invention includes a top deck, a bottom skid, and several posts for providing support between the top deck and bottom skid. The posts are integrated with either the top deck or bottom skid. Within each pallet post is a steel tube reinforcement that is overmolded directly into the bottom skid, or is assembled after the pallet post is molded. The supports, which are typically hollow posts, are molded onto either the top deck or bottom skid, and a thermoplastic weld or adhesive joint is applied to the posts to complete the assembly. The palled having the integrated posts and reinforcements provides an economical approach of reinforcing pallet posts to absorb tow fork impact.

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 welded joint for structural component having two or more portions fused together at a weld line. An adhesive layer is placed between the two or more portions at the location of the weld line and a conductor is placed between the two or more portions in operable contact with the adhesive. Energy is transmitted through the conductor and into the adhesive layer to activate the adhesive layer and create the weld line that defines the welded joints between the two or more portions. The welded joint of the structural component allows energy to be injected into the adhesive layer via the conductor in order to cause the adhesive layer to activate from the inside of the adhesive outward. The conductor can be placed adjacent the adhesive layer or within the adhesive layer in order to cause the adhesive to be activated from the inside outward.

Abstract: An implant applicator and method for positioning a resistive implant material on a first plastic component to be used to form a resistive implant weld between that first plastic component and a second plastic component. The resistive implant material is heated and pressed into a targeted surface of the first plastic component to tack the resistive implant into place. The second plastic component is positioned over the tacked resistive implant and a weld formed in a known manner. The resistive implant material can be heated for tacking by passing an electric current through it before it is pressed into the first plastic component by a second member or by contacting the resistive implant material against a separately heated surface prior to pressing it into the first plastic component.

Abstract: A method of forming members of fiber reinforced thermoplastic members via molding, the members including at least one hollow chamber, formed by water injection into the melt in the mold, to stiffen the finished member. The thermoplastic is preferably selected from a group comprising polypropylene, Nylon, PET, ABS, TPO, and thermoplastic polyurethane, while the reinforcing fibers are preferably selected from a group comprising glass, aramid, carbon, and natural fibers. Preferably, the extruded melt is produced such that the average length of the reinforcing fibers is less than four millimeters.

Abstract: A shipping pallet having a top deck, a bottom skid, and a plurality of posts disposed between and separating the top deck and the bottom skid such that at least one tow fork is able to be positioned between the top deck and the bottom skid. The shipping pallet also includes a plurality of collars formed as part of the top deck, and the posts are integrally formed as part of the bottom skid. Each of the plurality of posts is received into and connected to a respective one of the plurality of collars. There is also a plurality of reinforcements, and each of the reinforcements is disposed within and surrounded by a post. Each post and reinforcement is received into one of the collars, and the post is connected to the collar through a connection point, such as an adhesive joint or thermoplastic weld.

Abstract: A welded joint for structural component having two or more portions fused together at a weld line. An adhesive layer is placed between the two or more portions at the location of the weld line and a conductor is placed between the two or more portions in operable contact with the adhesive. Energy is transmitted through the conductor and into the adhesive layer to activate the adhesive layer and create the weld line that defines the welded joints between the two or more portions. The welded joint of the structural component allows energy to be injected into the adhesive layer via the conductor in order to cause the adhesive layer to activate from the inside of the adhesive outward. The conductor can be placed adjacent the adhesive layer or within the adhesive layer in order to cause the adhesive to be activated from the inside outward.

Abstract: An implant applicator and method for positioning a resistive implant material on a first plastic component to be used to form a resistive implant weld between that first plastic component and a second plastic component. The resistive implant material is heated and pressed into a targeted surface of the first plastic component to tack the resistive implant into place. The second plastic component is positioned over the tacked resistive implant and a weld formed in a known manner. The resistive implant material can be heated for tacking by passing an electric current through it before it is pressed into the first plastic component by a second member or by contacting the resistive implant material against a separately heated surface prior to pressing it into the first plastic component.

Abstract: A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

Abstract: A fused component having a first portion and second portion made of polymer material. Between the first portion and second portion is a conductor and a weld line is formed between said first portion and said second portion along the surface area of the conductor. The weld line has a strength of equal to or greater than 800 psi. The fused component formed can be any type of automotive component such as a tailgate, running board, roof rail, liftgate, or front end carrier.