Magna Exteriors Gmbh

Chrysler Corporation

Magna International Inc.

Mark Peter Birka

Christopher John Kuntze

Riad Chaaya

Stanislav Tichy

Heiner Salzmann

William J J Harney

Martin Robert Matthews

Anthony John Povinelli

Keijo Johannes Huotari

Michael A West

Keith G Korte

Peter G DeMarois

Gerald C Dermidoff

Daniel R Dobbs

Scott Varisto

Sinisa Andrasic

Paul Hasl

Jeremy K Dew

Charles T Parker

Andrew Cox

Marcus Ashmore

Kenneth J Williams

Jeff Rubis

Metal rib overmolding joining including creating geometrical features in reinforcements for interconnecting a three-dimensional metal reinforcement to a metal base plate of an overmolding part in order to transfer load forces. Interlocked reinforcement is pre-assembled or assembled in an injection molding tool. Geometric features are positioned and joined creating a connection geometry that is overmolded. The joints created between the metal reinforcements are done without a welding process.

Metal rib overmolding joining

A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.

Three dimensional overmolding

A modular gate combined with multiple functions which can be easily employed with existing tailgates without any hardware or mounting modifications to existing truck beds. There is provided a modular tailgate system having a tailgate portion in combination with a plurality of functions. The modular tailgate system integrates any combinations of at least two of the plurality of features without affecting existing body sides and/or existing truck beds. Integrated features include a multi-functional gate (e.g., swing, drop, etc), storage (e.g., normal, sealed, refrigerated, heated, etc), step(s), lighting (e.g., ingress/egress, bed interior, removable, trailer hitch, parking, etc), bed extension(s), power (e.g., 12 v and/or 110 v), tie downs (e.g., ratchets, anchors, etc), sawhorse, magnet(s), table(s), bench(es), seat(s), net(s), any other predetermined desired function, etc., and combinations thereof.

Modular tailgate

A liftgate () formed with a thermoplastic which is overmolded around preselected reinforcements at stress points, such as a corner area, which includes a pair of separate reinforcement plates () and wherein a 3-dimensional reinforcement plate () is connected between the pair of separate reinforcements (). Preferably the 3-dimensional reinforcement plate is connected to three reinforcements.

Overmolding assembly reinforcement bracket

A liftgate having an overmolded hinge point comprising a metal reinforcement overmolded with a polymer and having a compression limiter portion molded in. The compression limiter portion including a tubular portion for receiving a fastener encapsulated during overmolding and having overmolded gusset ribs extending therefrom during the overmolding process.

Revised mounting point

A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.

Infrared welded liftgate assembly and process of making same

An automobile panel that are formed using at least partially using a pultrusion forming process. Examples of automobile panels formed using pultrusion include, but are not limited to tail gates, roofs, hatches, doors, hoods, bed liners, floor liners, bed steps, running boards, bumper covers etc. The automobile panel includes a pultruded core panel formed of a polymer resin material having continuous fibers extending across a length of the pultruded core panel, wherein the pultruded core panel has a plurality of channels extending across a surface of the pultruded core panel, wherein the channels have openings at opposing ends of the surface. Also included is an interior finish panel connected to a first side of the pultruded core panel and an exterior finished panel connected to a second side the pultruded core panel.

Pultruded tailgate structure

A liftgate arrangement including a thermoplastic inner panel with an outer surface and an inner surface. The liftgate arrangement further includes one or more carbon fiber sheet mold compound reinforcements connected to and extending across a portion of the outer surface of the inner panel. The one or more carbon fiber sheet mold compound reinforcements also includes a channel extending between two openings on the one or more carbon fiber sheet mold compound reinforcements. The one or more carbon fiber sheet mold compound reinforcements are used to strengthen the inner panel at desired locations.

Liftgate arrangement having a carbon fiber reinforced sheet molding compound reinforcement

An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.

Infrared welded exterior panel assembly and process of making same

A molded vehicle component () having a skin () and a lower density core () formed by a co-injection molding process. In a first phase, a first material for forming the skin of class A surface material is injected into a mold to partially fill the mold cavity (). Thereafter, in a second phase, a second material is injected into the same cavity () to complete filling of the mold cavity (). The second material can flow only to portions of the part where the first material is still molten and displaces the molten core of the first phase, pushing it away from co-injection gates until the mold cavity is full. The second material is pre-treated with a chemical blowing agent in order to reduce part weight by foaming the core material. The finished co-injection molded part () has one material on all visible class A surfaces () and a core () that is a different, less dense material.

Co-injection of molded parts for weight reduction

A thermoplastic liftgate inner panel construction is provided by using a co-injected injection molding process. In a first phase, a class A surface material is injected into the molds and thereafter in a second phase an inner core of material is injected using a gas-infused reinforced polymer.

Co-injection molding of the structural portion of a vehicle liftgate inner panel

A plastic overmold aluminum extrusion including at least one plastic overmold and aluminum extrusion. The aluminum extrusion is formed with sufficient cross sectional properties and features such as an internal web to help prevent undesirable collapses under injection or compression molding pressures. This improves part geometry and strength while minimizing weight. A plurality of protrusions and/or local deformations on an outer wall of the extrusion can be used to create strong mechanical interface to the plastic. Localized deformations can result from a combination of the applied plastic pressure under injection or compression molding pressures and the proximity of outer gaps of the internal web structure. A process of making the plastic overmold aluminum extrusion includes inserting at least one aluminum extrusion into a mold without mandrels and delivering plastic forming the plastic overmold.

Plastic overmolding of aluminum extrusions

A bumper () created using a resistive implant welding process. The bumper includes a mounting plate portion () and a composite bumper portion (). The mounting plate portion () is connected to the composite bumper portion () using a resistive implant welding process. In one embodiment, the present invention includes a bumper for a vehicle having a mounting plate () and a bumper portion (). The bumper portion () includes at least one flange () formed as part of the bumper portion (), a first contact area () formed as part of the mounting plate (), and a second contact area () formed as part of the flange (). A connection point is used to bond the first contact area () and the second contact area () such that the mounting plate () is connected to the bumper portion ().

Growing community of inventors

Northville, MI, United States of America

Mark Peter Birka