Ford Global Technolgoies, LLC

Ford Motor Company Limited

Automotive Composites Consortium

University of Tulsa

Daniel Quinn Houston

Haibo Zhao

Ernest D Stiles

Ronald K Wlosinski

Amanda Kay Freis

Aindrea McKelvey Campbell

Richard Howard Wykoff

Rick H Wykoff

Edward M Hagerman

John M Henshaw

Matthew John Zaluzec

S George Luckey, Jr

Peter A Friedman

Carl Frederick Johnson

Feng Ren

Ann Marie Straccia

Timothy James Dawda

William Steven Stewart

Laura J Meyer

John C Doudican

Armando Matthew Joaquin

Steven George Luckey, Jr

Kelly Willson-Hackworth

Dies for forming components, such as sheet components, and methods of producing the dies are disclosed. The die may include a bulk material and a forming surface. A solid conductor may be formed in the bulk material. The solid conductor may be spaced from and extend adjacent to the forming surface and have a melting point that is greater than a melting point of the bulk material. The solid conductor may be configured to absorb heat from the forming surface. There may multiple solid conductors within the bulk material, for example spaced apart and extending along an axis. The solid conductor may be a bundle of carbon fibers, which may be pitch-based. The solid conductor may be conformal to the forming surface, for example, having a constant spacing therefrom. The solid conductor may be cast-in to the die during its production.

Cooling of dies using solid conductors

A glass bubble includes a hollow glass body having an outer surface with a diameter of between about 16 micrometers and about 25 micrometers and a surface roughness of about 0.01% to about 0.1% of that diameter. A low density sheet molding compound incorporating a plurality of glass bubbles and resin is also disclosed.

Glass bubbles and low density sheet molding compound incorporating said glass bubbles

An automotive assembly comprises a sheet molding composite (SMC) element comprising an SMC sheet body shaped into a generally smooth functional section and at least one generally planar bonding section. The bonding section comprises a textured surface impressed as a result of molding the SMC sheet body in a compression molding tool having a corresponding textured pattern. The textured surface has a predetermined surface roughness for increasing the effective surface area of the bonding section relative to a non-textured surface. The predetermined surface roughness is in a range from 0.25 R(&#x3bc;m) to 8.5 R(&#x3bc;m). A second element has a secondary bonding surface adjoining the bonding section of the SMC element. An adhesive joins the secondary bonding surface to the bonding section without requiring any pre-treatment of the bonding section.

Bonded sheet molding composite automotive components without surface pre-treatment

A method is provided for treating the outer surfaces of a plurality of glass bubbles. That method includes loading a plurality of glass bubbles into a processing vessel having a roughened lining and displacing the processing vessel so that the plurality of glass bubbles move against the roughened lining to thereby roughen the outer surfaces. Alternatively, or in addition, the glass bubbles are subjected to air plasma treatment to increase the surface energy of the glass bubbles.

Surface treatment of glass bubbles

In at least one or more embodiments, a system for scutching material fibers includes first and second plates defining a first cavity to receive and discharge material fibers, the first plate including a first number teeth extending into the first cavity and movable in a first direction, the second plate including a second number of teeth extending into the first cavity and movable in a second direction different from the first direction. Teeth as present in the first number and/or the second number of teeth may be spaced apart from each. In certain instances, the material fibers may be carbon fibers.

System and method for scutching material fibers

An assembly comprising a first composite fiber reinforced part that is joined to a second part by a clinch joint. The first part includes a first layer of resin that is reinforced with fibers and a second layer of resin that is devoid of fibers and applied to one side of the first layer of fiber reinforced resin. The second part contacts the first layer of the first part. The first part and second part are joined by a clinch joint including a pressed out portion that is pressed into a clinching portion. The second layer of resin contains the fibers in the first part. An alternative assembly has fiber-free intended clinch joint forming areas that extend through the first part. A method is provided in which a first part including a first layer of resin reinforced with fibers is molded with a second layer of resin on one side of the first layer is joined by a clinch joint to a second part.

Composite panel for joining with a clinch joint and method of forming a clinch joint

A method of joining parts together with a self-piercing rivet that is inserted through a part and partially through a second part. The second part includes a fiber-filled layer and a resin matrix layer that together form a composite part. A self-piercing rivet extends into the second part, but does not penetrate completely through the matrix layer. An assembly, including a first part and a second part that includes a reinforced layer and a resin layer in which a fastener is inserted, but does not extend through the second layer. A composite part including a first layer of resin matrix reinforces the filler and a second layer of resin matrix that does not include a filler and is more than 3 microns thick.

Method of fastening parts to a composite part

A creep testing fixture and method for applying a precise amount of constant tensile stress to a creep test specimen to allow for precise measurement of creep in the test specimen. The fixture includes first and second mounting grips for holding opposite ends of a test specimen. A frame supports the mounting grips for relative reciprocal movement toward and away from each other. A tensile spring is connected between the first and second mounting grips. The frame subjects a test specimen held between the mounting grips to tensile stress in response to axially inward force that the tensile spring applies to the frame.

Creep testing fixture and method

A fixture is provided for testing the shear strength of a longitudinal weld which interconnects a plurality of planar blanks forming a tailor welded blank. The fixture includes a first pair of triangular shaped face plates connected to one side of the tailor welded blank and a second pair of triangular shaped face plates connected to the other side of the tailor welded blank. Each of the face plates includes a transverse edge which extends across the longitudinal weld connecting the planar blanks. The fixture further includes each of the transverse edges having a first portion and a second portion spaced from and parallel to the first portion. The fixture also includes an isolation portion interconnecting the first and second portions of the transverse edges adjacent the longitudinal weld for isolating a portion of the weld whereby the isolated portion of the weld is tested for shear resistance by applying a tensile load to the first and second pair of face plates.

Fixture for testing shear strength in tailor welded blanks

A tensile test fixture for applying constant tensile forces to a tensile test specimen comprises two mounting grips, each mounted to one of two lever arms in a pivoted lever arm frame structure. One end of each lever arm is pivotally attached to a compression column while the other end of each lever arm is attached to one end of a force-applying assembly. The mounting grips are pivotally attached to their respective lever arms between the compression column and the force-applying assembly and are designed to hold opposite ends of a tensile test specimen. The force-applying assembly comprises stress and strain modules that are interchangeably installable into the force-applying assembly to selectively subject tensile test specimens to constant strain and constant stress.

Self-contained constant stress/constant strain test fixture

A method of eliminating scrubbing noise between metal to metal (or metal to ceramic) contact members that experience articulating swiveling interengagement at high force levels in excess of 5,000 psi. The method comprises: (a) preparing the interface to present at least one fresh mechanically adherable stiff surface; (b) thermally spraying a top coating thereonto consisting of at least one of (i) a self-lubricating metal, ceramic material or metal alloy, and (ii) a compliant metal; and (c) placing the coating interface into service to subject it to repeating articulating swiveling contact that functions to microweld the coating to the surface under normal operating conditions.

Durable noise suppressing coating between interengaging articulating

A molded article comprising a molded body and one or more layers of heat shielding material attached to the molded body and a method of making same. The heat shielding material is placed on localized areas of the molded article which are exposed to elevated temperatures. The molded article may be a fiber reinforced plastic (FRP) which comprises a fibrous material containing a resin or alternatively, the molded article may be a thermoplastic material with or without reinforcement.

Molded article with integral heat shield

A fiber reinforced article having an integrally molded heat shield is produced using a liquid resin injection molding technique. One or more layers of heat shielding material are placed adjacent a preform. The preform contains a non-porous inner core and a porous fibrous mat exterior surface. The core is either a foam core, blow-molded core or a metal reinforced core. The heat shielding material is at least partially porous and includes a heat insulating material and/or a heat reflecting material. The heat shield also contains a layer of nonporous insulating material designed to prevent liquid resin from passing therethrough. The preform and heat shielding material are placed in a mold and resin is injected into the mold to impregnate the fibrous mat and partially impregnate the heat shielding material so that the heat shielding material is integrally molded to the product.

Method of molding an article with integral heat shield

A molded article comprising a molded body and one or more llayers of heat shielding material attached to the molded body and a method of making same. The heat shielding material is placed on localized areas of the molded articles which are exposed to elevated temperatures. The molded article may be a fiber reinforced plastic (FRP) which comprises a fibrous material containing a resin or alternatively, the molded article may be a thermoplastic material with or without reinforcement.

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Dearborn, MI, United States of America

Daniel Quinn Houston