Abstract: The invention relates to reinforced composite inner roof panels of the sandwich-type having a cellular core. In a method for making a inner roof panel of the invention, a stack is formed that is made up of: an upper skin made of a reinforced thermoplastic material; a cellular core made of a thermoplastic material; and a bottom skin made of a reinforced thermoplastic material. The upper and lower skins and the cellular core are formed together and have regions of reduced thickness and regions of increased thickness that may provide head impact absorbing characteristics or form structural components of the passenger compartment. Examples of structural components that may be formed include HVAC ducts, wiring conduits, video display panel mounts or air bag receptacles.

Abstract: A bumper system includes an elongated beam configured to be operatively mounted to the frame of the vehicle. Also included is a foam portion that extends along a portion of the beam and a fascia surrounding the foam portion. The fascia and the foam portion are operatively attached to the beam. The foam portion has a plurality of recesses formed therein which extend through a predetermined thickness of an inside portion of the foam portion. An integrated cylindrical cell matrix is disposed with the recesses and is configured to absorb energy resulting from impact force applied to an external portion of the bumper.

Abstract: The invention relates to reinforced composite inner roof panels of the sandwich-type having a cellular core. In a method for making a inner roof panel of the invention, a stack is formed that is made up of: an upper skin made of a reinforced thermoplastic material; a cellular core made of a thermoplastic material; and a bottom skin made of a reinforced thermoplastic material. The upper and lower skins and the cellular core are formed together and have regions of reduced thickness and regions of increased thickness that may provide head impact absorbing characteristics or form structural components of the passenger compartment. Examples of structural components that may be formed include HVAC ducts, wiring conduits, video display panel mounts or air bag receptacles.

Abstract: A bumper system includes an elongated beam configured to be operatively mounted to the frame of the vehicle. Also included is a foam portion that extends along a portion of the beam and a fascia surrounding the foam portion. The fascia and the foam portion are operatively attached to the beam. The foam portion has a plurality of recesses formed therein which extend through a predetermined thickness of an inside portion of the foam portion. An integrated cylindrical cell matrix is disposed with the recesses and is configured to absorb energy resulting from impact force applied to an external portion of the bumper.

Abstract: A natural wood-covered plastic part, such as a vehicle part, and a method of manufacturing same. The natural wood-covered plastic part includes a one-piece thermoplastic elastomeric body or structural substrate and a plastic-wood composite of a thermoplastic material compatible with the thermoplastic elastomer of the structural substrate. The plastic-wood composite and the plastic part are placed together at a bonding station. A bottom contact surface of the plastic-wood composite bonds with a front contact surface of the structural substrate between the contact surfaces thereof. The plastic-wood composite and the structural substrate may be bonded together in one of several ways, such as injection molding, compression molding and thermal or chemical bonding.