A method of manufacturing a unitary energy absorbing structure for a vehicle includes providing a first mold having a cavity receiving a first mandrel and a second mold having a cavity receiving a second mandrel. At least one mandrel segment is positioned in the first mold cavity and cooperates with the first mandrel. One or more layers of composite material at least partially cover the first mold cavity, first mandrel, at least one mandrel segment and second mold. The unitary structure is formed from the first layer, the second layer and the third layer of composite material with the first mandrel, the at least one mandrel segment and the second mandrel in the first mold and the second mold.

The invention relates to a method for producing plastic components for a vehicle, wherein the plastic components are at least partially painted in a painting step and are subsequently connected to further components on the non-painted surfaces, wherein at least one region, which is used to connect to the further components, is freed of impurities by a removal method using laser light.

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.

A bumper for a vehicle, including at least one profile, in particular an open profile, from a first material, having at least one ribbed structure formed from ribs from a second material, the ribbed structure being disposed along the profile at least in portions and at least in portions being connected to the profile in a force-fitting, form-fitting and/or materially integral manner in order for the profile to be reinforced. The bumper meets the requirements set in the event of collision loads and can be optimized in terms of load is achieved in that the ribbed structure is formed from fiber-reinforced plastic and has at least one first region and one second region, which differ from one another in terms of at least one property.

A method for the production of an FMV hybrid component includes braiding a dry hybrid fibre thread onto a core element, where a hybrid fibre braid is formed, and obtaining a fibre core composite. The method further includes reshaping the fibre core composite and impregnating and consolidating the hybrid fibre braid on the core element.

An ultrasonic welding method for joining a first thermoplastic part and a second thermoplastic part without causing visible read-through on an exposed surface of the second part. The method includes arranging the first part on an inner surface of the second part. The inner surface is opposite the exposed surface. The first part has an interface portion contacting the inner surface. The method includes causing a horn of an ultrasonic welding stack to be pressed against the first part by applying ultrasonic energy oscillating at a frequency in a range of 45-70 kHz through the horn, to thereby join the first part and the second part together. The horn has at least one protruding distal portion configured to penetrate through the first part as the ultrasonic energy is imparted through the horn. The distal portion has a length longer than a thickness of the first part. A collapse distance of a weld formed at the interface portion is less than the thickness of the first part, to avoid read-through effects on the exposed surface of the second part.

The present invention is directed to a closed structural component and process for preparing the same.

An injection molding die includes a fixed die and a movable die that move in a die opening/closing direction relatively to each other. A cavity that is formed between the fixed die and the movable die in a die clamping state includes a lateral cavity portion that extends along the die opening/closing direction and a first orthogonal direction. The injection molding die includes a demolding core and a following core that define an end portion of the lateral cavity portion across the fixed die and the movable die in a second orthogonal direction. The demolding core and the following core are configured to be movable in the second orthogonal direction while defining the end portion of the lateral cavity portion across the fixed die and the movable die in the die clamping state, and to be engaged with the fixed die with substantially no play in the second orthogonal direction.

A method of manufacturing, packing and shipping a vehicle bumper having the steps of dispensing into a bumper mold a shape-memory composition to form an original shape of an integral shape-memory vehicle bumper having a middle portion and a first end and a second end both extending from opposite ends of the middle portion, the shape-memory vehicle bumper having the original shape fitting in a first shipping box; applying force to the shape-memory vehicle bumper such that to cause a conversion of the original shape into a deformed shape of the shape-memory vehicle bumper, the deformed shape fitting into a second shipping box that is a fraction by volume of the first shipping box; placing the shape-memory vehicle bumper having the deformed shape into the second shipping box; and sealing and shipping the second shipping box.

A two different process continued performance type product assembly device may include a punching jig having a punch and configured to ascend and descend, a punching tool located on a lower portion of the punching jig and having a punching die that is located below the punch during a punching work, a fusion tool located on the lower portion of the punching jig and having a fusion horn that is located below the punch during a fusion work, and a tool exchange cylinder configured to push the punching die so that the fusion horn secedes from a position below the punch during the punching work and to pull the punching die so that the fusion horn comes into the position below the punch during the fusion work.