Vehicle part and method of making same
OwnerBrian P. Skarb, Terrence D. Gibney Jr +2inventors
InventorsBrian P. Skarb, Terrence D. Gibney Jr, Richard D. George, Michael J. Berta
Life of this patent
Estimating the term…
Abstract
A part for use with a vehicle includes a structural member made of foamed plastic material. The part also includes an expanded polypropylene substrate integrally attached to the structural member. Furthermore, the substrate cooperates with the structural member to provide a sufficient structural characteristic to the part.
Claims50
A part for use with a vehicle, the part comprising:
- a structural member made of foamed plastic material;
- and
- an expanded polypropylene substrate integrally attached to the structural member, wherein the substrate cooperates with the structural member to provide a sufficient structural characteristic to the part.
A door assembly for use with a vehicle door outer structure, the module comprising:
- a first portion adapted to be attached to the outer structure and including a first structural member made of foamed plastic material, a first substrate integrally attached to the first structural member and formed from expanded polypropylene, and a first cover material covering at least a portion of the first substrate and configured to face a vehicle interior compartment when the first portion is attached to the outer structure.
A method for making a part for use with a vehicle, the method comprising:
- positioning a structural member in a mold, wherein the structural member comprises foamed plastic material;
- introducing expanded polypropylene beads into the mold proximate the structural member;
- and
- causing the expanded polypropylene beads to adhere to each other in the mold so as to form a substrate that is attached to the structural member, wherein the substrate cooperates with the structural member so as to provide a sufficient structural characteristic to the part.
A method for making a door module for use with a vehicle door outer structure, the method comprising:
- positioning a structural member in a mold, wherein the structural member comprises foamed plastic material;
- introducing expanded polypropylene beads into the mold proximate the structural member;
- causing the expanded polypropylene beads to adhere to each other in the mold so as to form a substrate that is attached to the structural member, wherein the substrate cooperates with the structural member so as to provide a sufficient structural characteristic to the door module;
- and
- attaching a cover material to the substrate so as to provide an appearance surface that is adapted to face a vehicle interior compartment when the door module is attached to the outer structure.
Dependencies are inferred from the claim text.