Abstract: There is provided a vehicle skeleton member including a composite material of a thermoplastic resin and a carbon fiber, wherein the composite material is a unidirectional carbon-fiber composite material (A) that a form of the carbon fiber in the composite material is a continuous fiber aligned in one direction and/or a random carbon-fiber composite material (B) that a form of the carbon fiber in the composite material is a discontinuous fiber arranged two-dimensionally randomly.

Abstract: A light-weight vehicle component such as a vehicle chassis (100) formed from an internally reinforced rigid closed-cell foam (12). The reinforced closed-cell foam vehicle chassis (100) includes an outer layer of rigid closed-cell foam (108a), an inner layer of rigid closed-cell foam (108c), and one or more layers of reinforcing structural material (114) disposed between the inner and outer layers of foam. The reinforced closed-cell foam vehicle chassis incorporates reinforced attachment points (114a) for receiving and supporting vehicle components, such as suspension elements, steering components, a drive motor, and passenger accommodations.

Abstract: A component such as a vehicle exterior part having a transparent area without creating gaps is produced by introducing a hole into a film for the transparent area, inserting the film into a component mold, and then back-molding the same with a transparent plastic material in the mold such that the hole is filled with the transparent plastic material.

Abstract: A process for continuous, tailored lamination of aligned composite materials in such a way that either pre-formed or pre-consolidated sheets are made available for subsequent infusion molding or stamping processes, the process comprising the steps of: material placement, consolidation/stabilization, cut and kit, fabrication, and final trim. A tailored blank machine is also described. The blank machine includes a series of material placement heads arranged in a linear or serial fashion along a single moving placement table, wherein each head lays down a single angle of the prescribed stacking sequence as the conveyer passes under the head at a constant speed wherein the angle is proportional to head traverse rate divided by conveyer speed.

Abstract: An improved elongate aluminum alloy product, and a method of producing such a product, ideally suited for use as a component in a vehicle frame or subassembly, i.e., body-in-white. The alloy consists of essentially 0.45 to 0.7% magnesium, and about 0.35 to 0.6%, silicon, and about 0.1 to 0.35%, vanadium, and, 0.1-0.4% iron, preferably 0.15 to 0.3%, the balance substantially aluminum and incidental elements and impurities.

Abstract: A truck trailer cover 40 includes a multi-layered article 10 that is dimensioned and adapted to be fitted over and secured to a truck trailer 42. The multi-layered article, 10 includes a fabric 12 having a polymeric sheet 14, 16 secured to each side of the fabric 12. Each polymeric sheet 14, 16 secured to the fabric 12 has two non-chlorinated polymeric layers. The first non-chlorinated polymeric layer A, A' is disposed on the inner side of each sheet and contains an ethylene copolymer that has a Shore A hardness less than 85. The second non-chlorinated polymeric layer B, B' is disposed on the outer side of each sheet and contains a polymer having a Shore A hardness greater than 85. The multi-layered article 10 demonstrates good flex-crack resistance to make it suitable for use in a roll-up sign 30 or a truck trailer cover 40.

Abstract: A roof material for motor vehicles includes an upper fabric, a lower fabric and a rubber layer arranged between them. The upper fabric includes polyacrylonitrile warp and filling threads. The warp threads are endless filaments (multifilaments). The upper fabric has a protective, polymeric coating on its top side. The rubber layer includes two rubber layers with an intermediate layer of high-strength material.

Abstract: A method for enhancing the surface appearance of thermoset FRP wherein a thin rubbery coating is applied to a sheet molded compound (SMC). This coating, when applied to FRP inhibits propagation of micro cracks to the surface of compliant rubbery coating of the parts, while not sacrificing the physical properties of the molded parts. The coating also supplies a suitable smooth surface for automotive body panel applications that serves as a substrate for further paint applications.