The Budd Company

Richard B Freeman

Bruce N Greve

Jack J Ritchie

Terry L Ingham

Joseph A Bodary

John J Morse

Walter S Eggert, Jr

Mark C Handley

Stephen E Rawe

Earl E Kansier

Herbert A Jahnle

Donald L Flagg

David Djavairian

Charles W Goetz

Jr Eggert Walter S

A hydroformed member having internal reinforcements and method of manufacturing the same. The method includes the steps of providing a die having a tooling cavity and a pair of opposing rams disposed in the tooling cavity. A tubular member is enclosed within the tooling cavity. The pair of opposing rams are then driven against opposing sides of the tubular member to form a pair of opposing indentations therein. While the rams remain in place, hydraulic fluid pressure is then applied within the tubular member causing the walls of the tubular member to closely conform to the shape of the tooling cavity and the pair of opposing rams.

Internal hydroformed reinforcements

A transfer/injection molding apparatus is defined that includes a charge forming unit, a molding unit and a charge overflow unit. The charge is formed so that the fibers therein are randomly oriented in substantially parallel horizontal planes such that they are always substantially parallel to the direction of initial flow into the cavity of the molding unit. Excess charge from the cavity is forced into the charge overflow unit, which is selectively located in an area where surface finish is less critical. The excess charge displaces an overflow pin, which is kept upwardly biased, under molding pressure, to be flush with the lower inside wall of the molding unit cavity.

Molding apparatus with charge overflow

A forming device including discreet heating zones along the axial length and circumferential portion of a mold cavity. One zone can be heated to cause the heated tube portion to become more elastic than the non-heated tube portions. As a result, less axial force and radial pressures are required in order to provide the necessary metal deformation against the mold halves. Preferably, the heating zones are provided by way of a series of induction coils disposed along the axial length and circumferential portion of the tube. Each induction coil can be individually energized so that select portions of the tube are heated in a controlled manner.

Forming technique using discrete heating zones

A composite fiber reinforced plastic (FRP) bumper includes an energy absorbing outer shell which is spaced from a rigid inner beam. The outer shell deforms under low impact loads and serves as an energy absorber. Upon high impact loads, the shell abuts the inner beam which, in turn, transfers the loads to the vehicle frame.

Hollow FRP bumper

An automated transfer/injection molding apparatus and process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.

Automated thermoset molding apparatus

A method and apparatus of producing and using composite fibers in a liquid molding process. The composite fibers are formed from a base material and filler particles which are lighter or less expensive than the base material. A preform screen is placed at the bottom of a tank. The tank is filled with liquid, the composite fibers and a mass of reinforcing fibers creating a slurry above the screen. The screen is raised up through the slurry causing the composite fibers and the reinforcing fibers to be deposited on the screen creating a fiber preform. The preform is then removed from the screen and is placed in a mold for use in a liquid molding process.

Process of producing preforms containing light weight filler particles

An automated transfer/injection process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.

Automated thermoset molding method

A method of molding an outer body panel and attaching that outer panel to an inner supporting portion of a vehicle. The outer panel is made in a mold having a mold cavity and a plurality of passages extending outwardly from the cavity. During the molding process, ejector pins disposed within these passages are used to provide supplemental pressure within the mold cavity and prevent shrinkage. After the material within the mold has solidified, the mold is opened and the ejector pins are used to eject the outer panel from the mold. Locating members formed in the passages are used to locate and maintain the outer panel in a fixed relationship with respect to the inner supporting portion when they are assembled and bonded to one another.

Outer door panel and method for molding and attaching same

A hybrid vehicle assembly, and more particularly, a hybrid truck assembly including a hybrid passenger cab shell and a hybrid truck box are disclosed. The hybrid passenger cab shell includes a first plurality panels which are assembled together to form an inner cab shell and a second plurality of panels which are assembled together to form an outer cab shell. Generally, at least one of the first or second pluralities of panels are formed from a plastic material such as a sheet molded compound (SMC). Similarly, the truck box portion of the vehicle is formed from a plurality of inner panels which are formed from a plastic material such as SMC and are assembled together along overlapping edge portions. Thereafter, a plurality of outer panels are attached to the respective inner panels.

Hybrid vehicle

A one-piece cast suspension mounting spring pocket having a circular, radially contoured disk portion and having a plurality of flanges is disclosed. The disk portion serves as a spring pocket and prevents a spring from radial movement. The flanges are parallel to and spaced from one another, and are generally perpendicular to the disk portion of the one-piece cast member. One or more of the flanges intersects a frusto-conical formation which is radially centered in the disk portion, the intersecting flange conforming to and bowing with the frusto-conical formation. The structural integrity of the one-piece cast spring pocket is improved when compared to the currently produced multi-piece spring pockets by having the flange intersect the frusto-conical section.

Spring pocket suspension mounting assembly

A fiber reinforced plastic fuel tank includes a multipurpose inner liner that serves as an aid during molding as well as a corrosion resistant protector and/or secondary fuel container for the tank when in use.

Composite fuel tank

A vehicle door assembly including a tailored steel inner panel and an panel spaced apart by a belt-line reinforcement member. The tailored steel inner panel includes an intrusion beam which bridges first end and second ends of the inner panel.

Composite door assembly

An intrusion beam structure for reinforcing a vehicle door includes an elongated member adapted to be attached to a surface of the inner panel of a door frame that is substantially parallel to the axis defined by the elongated member. The elongated member includes first and second end portions interdisposed by a middle portion. The end portions are substantially identical and each taper away from the middle portion. In a first embodiment, the elongated member is unitarily formed and has a substantially circular cross-section. In a second embodiment, the elongated member includes first and second bar portions which substantially traverse the entire length of the elongated member and are disposed substantially parallel to each other. The first and second bar portions are separated by an intermediate structure.

Tapered intrusion beam for reinforcing a vehicle door

A method and apparatus are disclosed for bonding a multi-panel device together by injecting a liquid adhesive into a flow channel created by a hem flange located along a perimeter of two contacting panels. The adhesive is then cured and thus forms a permanent bond between the panels.

Bonding technique for a multi-panel device

An intrusion beam structure for reinforcing a vehicle door includes an elongated member adapted to be attached to a surface of the inner panel of a door frame that is substantially parallel to the axis defined by the elongated member. The elongated member includes first and second end portions interdisposed by a middle portion. The end portions are constructed of a first material, and the middle portion is constructed of a second, different material. The elongated member is unitarily stamped from a composite sheet and is formed to include first and second mounting members, each having a planar surface adapted to mount to the inner panel.

Growing community of inventors

Oxford, MI, United States of America

Richard B Freeman