Borgwarner Inc.

Other

Richard W Roberts

Dwight L Tothero

John E Nemazi

Mark J Fogelberg

Frederic H Abendschein

John Saxon Ivey

Ralph D Salle

Edmund J Klimek

David E Bearint

A fireproof safe cover designed to provide protection against fire, excessive heat, and smoke for safes such as gun safes used for storing valuable items. The cover includes a rear wall, side walls, a top surface, and a zippered front surface and can be slipped directly over a safe in a closed orientation with front surface zippered/fastened. The zippers mounted along opposing edges of the front surface can be unfastened for easy access of the safe in an open orientation. The cover is available in different sizes and colors and is made of fire-resistant material to safeguard the safe and its contents. The rear wall of the cover has openings for electrical wiring, and the cover can be personalized with embroidered logos or indicia. In some embodiments, the cover has recessed, reinforced, and/or pass-through areas for easy access of the safe and to accommodate protrusions of the safe.

Fireproof safe cover

A run-flat tire insert for installation in a pneumatic tire mounted on a rim. The insert is a one-piece toroidal member formed from expanded polymer foam beads molded into a structural foam part. The insert has an inner diameter surface sized to fit snuggly about a periphery of a tire rim and an outer diameter sized to fit within a tire cavity. The insert is spaced from the tire inner casing surface during normal operation and supports the tire inner casing surface away from the rim in the event of a flat tire. A molding apparatus and a method of forming a run-flat tire insert is also disclosed.

Run-flat tire insert

A plastic article is recited having a plastic shell including walls defining a cavity. Within the cavity is an in-situ foam core including expanded polymer beads. A layer of the expanded polymer beads includes a layer of distorted beads adjacent to the walls. The in-situ foam core has a thermal bond to the walls.

Method for making a running board having an in-situ foam core

The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section there between and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity. The bead and shell are of a similar plastic composition enabling the articles to be reground and recycled. An apparatus for forming the articles and an associated method of manufacture are also disclosed. A thermal management system includes a panel having a periphery, and a skin having a thermal bond to an in-situ foam core. The panel has a thermal transmittance u-value ranging from 0.1 to 0.17 W/m&#xb0; C.

Recyclable Plastic structural articles and method of manufacture

The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section there between and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity. The bead and shell are of a similar plastic composition enabling the articles to be reground and recycled. An apparatus for forming the articles and an associated method of manufacture are also disclosed.

Recyclable plastic structural articles and method of manufacture

An in-situ foam core component having first and second opposed thermoformed skins each having a thermal bond to an in-situ foam core disposed there between. At least one embossment In one of the skins joined to the other skin forming a pinch off junction. A through hole is formed in the pinch off junction sized to receive a fastener so that the embossment provides a sleeve structure which can transmit load between the first and second skins when the in-situ foam core component is attached to a member using a fastener extending through the hole.

In-situ foam core stress mitigation component and method of manufacture

An in-situ molded foam core structural plastic article having an outer shell with an interior cavity filled with expandable polymer beads which when expanded substantially fill the interior cavity forming a thermal bond with the shell. The bead and shell are of a similar plastic composition enabling the articles to be reground and recycled. Various articles are disclosed including structural panels, and automotive seat, load floor, interior panel, bumper and running board components. An apparatus for forming the articles and an associated method of manufacture are also disclosed.

A floor support structure for a bathtub or a shower tray floor, taking the form of a separate element to be used in conjunction with a traditional bathtub or shower tray floor, or as a unitary shower tray floor formed with the support structure integrated therein. The supports include a hollow plastic shell having a lower surface for lying on a planar subfloor, an upper surface contoured to the desired shape and a peripheral sidewall extending there between. Preferably, a drain hole is formed in the plastic shell which also interconnects the upper and lower surfaces thereby defining a hollow interior cavity. The cavity is filled with expandable thermoplastic foam beads which are expanded in place with steam in order to substantially fill the interior cavity thermally bonding the beads together and to the shell interior wall. The expanded foam bead is capable of being compressed without substantial permanent set.

Bathtub/shower tray support

An elongated structural article, having a continuous profile extrusion with spaced apart layers defining a portion of a cavity filed filled with thermoplastic pre-expanded beads expanded with steam in-situ causing the beads to securely bond together and to the profile extrusion. The article is cut to a length forming ends having an exposed foam core. A system for manufacturing the article is also disclosed having a profile extrusion die for forming an axially profile defining a wall surrounding a cavity, a tubular shaping mold located axially downstream of the extrusion die sized to support a length of the profile as it passes there through. A bead dispenser is oriented to introducing pre-expanded beads into the profile cavity while within the shaping fixture and a steam tube is oriented downstream of the introduction of pre-expanded beads. Control valves regulate the flow of pre-expanded beads and steam into the profile cavity.

In-situ foam core structural articles and system for forming

In at least one embodiment, a plastic article comprises a first plastic layer having a periphery and defining a cavity. An expanded polymer particle core is formed in-situ and heat-bonded to the cavity. The expanded polymer particle core has an apparent bulk density ranging from 1 lb/ftto 20 lb/ft. The article supports a dynamic load or static load exceeding 1.3 lbf/in.

Structural plastic articles, method of use, and methods of manufacture

A method of manufacturing an elongated article is recited to include extruding a first and a second layer each having peripheries. The second layer is spaced apart from and opposed to the first layer. Together, they define a cavity between them. Into that cavity particles are dispensed. The particles are expanded with an expansion fluid to form an in-situ foam core and to thermally bond the in-situ foam core to the first and second layers. The first and second layers having the thermal bond to the in-situ foam core are shaped to form the article. An elongated article from this process is also recited.

In-situ foam core structural articles and methods of manufacture of profiles

A seating system for use with a vehicle includes a first seat component having a skin having a thermal bond to an in-situ foam core. The first seat component maximum displacement is less than 160 mm when tested according to a test method in ECE R17 regulation for luggage retention with a 20 times the force of gravity crash pulse. A method of manufacture the seat back system is also recited.

In-situ foam core vehicle seating system and method of manufacture

An energy management system for use with a vehicle having an interior includes an elongated plastic member having a wall defining a cavity. Disposed within the cavity is an elongated first in-situ foam core member, which has a first thermal bond to the wall. The wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion. A second in-situ foam core member is connected to at least a portion of the elongated plastic member forming the energy management system. The energy management system is capable of passing a 5-mph crash test passing Federal Motor Vehicle Safety Standard 215 (FMVSS 215) Phase II.

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Lombard, IL, United States of America

Richard W Roberts