Magna International Inc.

Alan C Cave

Dwight K Buckle

Robert Dernovsek

Lawrence G Landrith

Darrel S Vassallo

Fabian Farkas

Jimmy M Escedi

William S Kemeny

Ben Zywicki

Richard W Haveman

Antoine Zafera

Danny Grunsted Solberg Jensen

The present invention is directed to an energy absorbing component externally mounted to a vehicle having a beam structural member and at least one energy absorber operably connected to the beam structural member. The energy absorber absorbs energy when the vehicle undergoes a collision. Also included is a beam cover plate connected to the beam structural member through the use of resistive implant welding, which simplifies the manufacturing process, and improves manufacturing costs. There are two vehicle attachment plates which are overmolded to the beam cover plate, the vehicle attachment plates allow for the beam cover plate to be attached to a vehicle. The beam cover plate, beam structural member, and energy absorber form a component that is operable to function as a bumper that is connected to a vehicle, which absorbs energy during a collision.

Bumper beam with integrated energy absorber

The invention provides an article, a method and an apparatus of forming expanded plastic materials in a steam chest mold having out of die draw features. This is achieved by means of a cavity pull system. The cavity pull system allows for the provision of molded features outside the die draw and is designed to operate on a cam type system using two stainless steel rods running at a right angle to one another. A gear mechanism allows molded features, e.g. holes, to be formed at any angle on any part design where enough part geometry exists to accommodate the forming features and in the tool for mechanism components. The invention is advantageously employed in the formation of holes outside the die draw in vertically stacked injection tools for energy absorbers used in vehicle bumper fascias. The provision of out of die draw molded features is useful for fascia component locating or attachment.

Article, method and apparatus of forming expanded plastic materials in a steam chest mold

The invention provides an automotive vehicle plastic panel including a show surface and a hidden surface opposite the show surface. A molded fastener is foldably joined to the plastic panel by a living hinge. The molded fastener, the plastic panel and the living hinge are integrally formed. The molded fastener has a base and a clip member supported on the base. The molded fastener can be fastened to the plastic panel by folding the molded fastener about the living hinge so that the molded fastener engages the hidden surface of the plastic panel in an install position. The clip member is used to fasten the automotive vehicle molding, such as a rocker panel, to a vehicle.

Vehicle body panel with integral clip

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Mount Forest, Canada

Alan C Cave