Meritor Light Vehicle Systems, Inc.

Nick Kalageros

Rainer Grimm

Roch J Tolinski

Laurent Arquevaux

Steven M Foster

Holly Ann Giangrande

Carmelo Mondello

Charlie Hopson

The body panels of the present invention are designed to crumple in a predisposed manner upon impact. The body panels are preferably made from a polymeric material. Further, the body panels can include a sheet of colored material attached to the polymeric material so that no painting of the panel is necessary. Preferably, the colored material is on an exterior surface of the panel. The colored material could be made from a thermoplastic with molded in color. The preferred embodiment of the present invention includes a polymeric material reinforced with spaced reinforcing fibers. An alternative embodiment of the body panel includes a sheet of polymeric material that is reinforced with spaced mechanical ribs that are preferably molded into the sheet of material. Another alternative embodiment of the body panel includes alternating sections of high density polymeric foam and low density polymeric foam. Yet another alternative embodiment of the body panel includes a sheet of foam material, preferably polymeric, that is reinforced with spaced metal inserts. The metal inserts are preferably notched to yield in a predetermined manner.

Crumple zone for body panels

A vehicle pick-up bed is disclosed that can be folded into shape by hand. The pick-up bed includes a generally flat sheet of colored material molded together with a generally flat sheet of reinforced polymeric material. Preferably, the sheet of colored material is placed in the mold and the reinforced polymeric material is injected into the mold, onto the back of the colored sheet. During the molding process, the reinforced polymeric material and the colored material are formed or molded into a single, generally flat, solid component. The sheet of colored material adheres to the reinforced polymeric material. Once molded, the sides of the pick-up bed are folded into shape along hinge edges and connected to stay in place. Hinge edges could be formed by locating few or no reinforcing fibers in the reinforced polymeric material in the desired location of the hinge edges. The colored material is preferably.a paintless polymer film. Alternatively, the colored material is pre-painted aluminum. As a result of using either of these two options, there is greater flexibility in adding color to the vehicle. Due to the injection molding process, additional features can be directly molded into the component. For instance, a drainage system, brake light attachments, brake light covers, wiring conduit, fender attachments, or a cargo cover can be directly molded into the reinforced polymeric backing material during the molding process.

One piece molded pick-up bed

A vehicle pick-up bed is disclosed that can be folded into shape by hand. The pick-up bed includes a generally flat sheet of colored material molded together with a generally flat sheet of reinforced polymeric material. Preferably, the sheet of colored material is placed in the mold and the reinforced polymeric material is injected into the mold, onto the back of the colored sheet. During the molding process, the reinforced polymeric material and the colored material are formed or molded into a single, generally flat, solid component. The sheet of colored material adheres to the reinforced polymeric material. Once molded, the sides of the pick-up bed are folded into shape along hinge edges and connected to stay in place. Hinge edges could be formed by locating few or no reinforcing fibers in the reinforced polymeric material in the desired location of the hinge edges. The colored material is preferably a paintless polymer film. Alternatively, the colored material is pre-painted aluminum. As a result of using either of these two options, there is greater flexibility in adding color to the vehicle. Due to the injection molding process, additional features can be directly molded into the component. For instance, a drainage system, brake light attachments, brake light covers, wiring conduit, fender attachments or a cargo cover can be directly molded into the reinforced polymeric backing material during the molding process.

A vehicle pick-up bed with fenders is disclosed that can be folded into shape by hand. The component includes a generally flat sheet of colored material and a generally flat sheet of reinforced polymeric material. Preferably, the sheet of colored material is placed in the mold and the reinforced polymeric material is injected into the mold, onto the back of the sheet of colored material. During the molding process, the reinforced polymeric material and the colored material are molded into a single, generally flat, solid component. The sheet of colored material adheres to the reinforced polymeric material. Once molded, the sides of the pick-up bed and fenders are folded into shape along hinge edges. The side walls are connected to stay in place. Hinge edges could be formed by locating few or no reinforcing fibers in the reinforced polymeric material in the desired location of the hinge edges. The colored material is preferably a paintless polymer film. Alternatively, the colored material is pre-painted aluminum. As a result of using either of these two options, there is great flexibility in adding color to the vehicle. Due to the injection molding process, additional features can be directly molded into the component. For instance, a drainage system, brake light attachments, brake light covers, wiring conduit or a cargo cover can be directly molded into the component.

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West Midlands, United Kingdom

Nick Kalageros