The invention relates to a monobloc part forming a front block for motor vehicle including a structural portion forming an energy absorption system, and a moulded semi-structural portion forming at least an aerodynamic system, the semi-structural portion being overmoulded on the structural portion.

A force-attenuating system that is interposed between an exterior surface and an interior surface, either or both of which may be subjected to percussive forces. The system has a ceiling that is positioned proximate the exterior surface and one or more inverted hat-shaped force-attenuating units with sidewalls extending inwardly convergingly away from the ceiling. Some of the units have a floor that is positioned proximate the interior surface. Optionally the force-attenuating units may be configured as clover-leaf structures with a central region and hemi-pear-shaped lobes extending therefrom. Within the lobes is a floor that is positioned proximate the interior surface. The force-attenuating system may be deployed in an automotive or non-automotive environment.

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 granulation method that can be used to obtain a polymer from post-consumer materials, and a motor vehicle part made from polymers produced by recycling used polymers.

A metallic polypropylene resin composition is provided herein. The metallic polypropylene resin composition provides appearance characteristics that are similar to those provided by painting, but without painting. The metallic polypropylene resin composition of the present invention has excellent physical properties such as scratch resistance, and thus may be applied to molding methods, such as a molded in color (MIC) method. The resin composition is useful as a material for automobile interior and exterior parts, as wells as electric and electronic products, which can be molded by the MIC method.

Systems and methods for forming 3D plastic parts that are cost effective in low volume, have excellent fit and finish, and use many components from 2D construction are disclosed. The systems and methods involve selecting a design and modelling the design. The design comprises 2D and 3D components of plastic parts. A 3D forming buck corresponding to the 3D component is manufactured. At least one of a 2D part and the 3D forming buck may be heated. The 2D part may be loaded onto the 3D forming buck for a predefined period of time. The 3D part formed after the loading may be separated from the 3D forming buck. The 3D part is the 2D part generally having taken the shape of the 3D forming buck. The 3D part may be cooled to obtain an end product.

A bracket presenter for an ultrasonic welder includes a one-piece first bracket portion and a one-piece second bracket portion mounted relative to one another. First and second tapered features are respectively provided by the first and second bracket portions and are nested relative to one another. The first and second tapered features engage in an extended position and are spaced from one another in a compressed position to provide a clearance enabling the first and second bracket portions to float lateral relative to one another. A spring biases the first and second bracket portions apart.

A molded part includes a plurality of surfaces and an embossment extending from one of the plurality of surfaces. The embossment includes a body and a bore extending through a central portion of the body. The embossment further includes a first pocket extending through a sidewall of the body and into the bore and a second pocket extending through an opposite sidewall of the body and into the bore. The first pocket and the second pocket each define inwardly tapered walls. The first pocket and the second pocket are spaced axially along the body and are diametrically opposed.

A method is disclosed for manufacturing a bumper structure. A blank made out of fiber-reinforced composite material is deep drawn in a molding tool to form a bumper cross member having a first groove. A first rib structure is molded in the first groove onto the bumper cross member in the molding tool.

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.