Abstract: In at least some implementations, a gear shift actuator assembly to cause gear changes in a vehicle transmission includes a drivetrain having a plurality of gears, a body that defines an output of the assembly, and a rotation sensor element coupled to the body. The body is driven by the drivetrain for rotation about an axis. The output has a coupling feature adapted to be connected to a transmission shift mechanism so that rotation of the output causes a transmission gear shift, and the coupling feature is located at an axial end of the body. The rotation sensor element is coupled to the body for rotation with the body, and the rotation sensor element is coupled to the body axially spaced from the coupling feature. In at least some implementations, the rotation sensor element includes a magnet.

Abstract: A method for controlling access to a vehicle, the vehicle being equipped with an access module and a keypad, an user having a portable device configured to communicate with said access module, the access module being designed to determine a relative position of the portable device with respect to the vehicle, the keypad being positioned outside the vehicle, wherein when the access module detects that the portable device is inside the vehicle and is in an inactive state, wherein said portable device is unable to authorize user access to the vehicle and start of the vehicle, then vehicle unlocking is authorized by a multiple switch operation in a predetermined sequence on the keypad, and wherein after vehicle unlocking, the access module puts the portable device in an active state, wherein said portable device is able to authorize user access to the vehicle.

Abstract: In at least some implementations, an actuator includes a motor, an output rotated by the motor about an axis, and a housing having an interior in which the motor and electrical component are received. The housing includes a first housing part and a second housing part coupled to the first housing part to define at least part of the interior. The first housing part has a first mounting surface and the second housing part having a second mounting surface arranged to overlap the first mounting surface when the second housing part and first housing part are coupled together and wherein the first mounting surface and second mounting surface are both arranged at an acute angle relative to a plane perpendicular to the axis.

Abstract: A battery tray assembly for a battery powered vehicle includes a tub having a bottom wall connected with a side wall. A side rail assembly is connected to the side wall of the tub. A lower impact rail is connected to the side rail assembly. The lower impact rail extends beyond the bottom wall of the tub. The lower impact rail is removably connected to the side rail assembly by a fastener.

Abstract: A component assembly includes a printed circuit board having an electronics component mounted on a first portion of a first face of the printed circuit board. A light emitting diode is mounted on a second portion of the first face. A light guide of a light transmissive polymeric material covers the body including the light emitting diode and the electronics component. The light guide includes: a cavity having the electronics component positioned within the cavity; a non-planar area of the light guide positioned above the cavity, the non-planar area mitigating against collapse of the light guide into the cavity; and a second cavity having the light emitting diode positioned within the second cavity; and a top plate of a polymeric light reflective material mounted onto the light guide directly above the light emitting diode.

Abstract: A molded component assembly includes a printed circuit board with a first face and an oppositely facing second face. Multiple light emitting diodes are mounted on a first portion of the first face. Multiple electronics components are mounted on a second portion of the first face. A light guide of a light translucent polymeric material has a contact surface directly contacting the first portion of the first face and multiple light outlets defining cavities in the light guide. The light guide is seated over the light emitting diodes and directly receives visible light from the light emitting diodes and transmits the visible light to the light outlets. A reflector plate directly contacts the light guide and extends over the second portion including the electronics components, and includes filler members extending into the light guide. The reflector plate reflects visible light back into the light guide.

Abstract: A battery tray for a battery powered vehicle includes a battery tray having a side wall. An impact absorbing structure is connected to the side wall. The impact absorbing structure includes at least one roll-formed member fixed to the side wall. The at least one roll-formed member is created from a single metal plate and includes a first plate portion roll-formed to create a first cavity and having a first flange created in a member central wall of the first plate portion. The first flange is fixed to the first plate portion. A second plate portion is roll-formed to create a second cavity and has a second flange at an end of the second plate portion fixed to the member central wall. A roll-formed U-shaped attachment member is fixed to the at least one roll-formed member.

Abstract: A battery pack safety system for a battery powered vehicle includes a vehicle battery pack having at least one battery cell positioned in a bay of a frame. Multiple sensors are each supported by the frame. A safety module in communication with each of the multiple sensors collects an output of each of the sensors for transmission to a vehicle computer unit. A safety module power supply provides backup power for operation of the multiple sensors and the safety module when an electrical charge of the battery pack is unavailable. A warning module is in communication with the safety module. The warning module when initiated by a signal from the safety module in response to an output signal generated by any of the multiple sensors energizes a signaling device providing external vehicle indication of a status of the battery pack.

Abstract: A printed film with mounted light emitting diodes encapsulated in a light guide includes a printed film assembly. The printed film assembly includes multiple light emitting diodes. A light guide is injection molded onto a first side of the body covering the light emitting diodes. A light transmissive polymeric material coating layer is applied by injection molding to a second side of the body opposite to the first side. An overmolded component has the printed film assembly embedded therein, with the coating layer exposed for visibility of light from the light emitting diodes when at least one of the light emitting diodes is energized.

Abstract: A roof rail connectable to a roof of a vehicle includes a substrate connected to the roof of the vehicle, and a modular cover having a first cover connected to the substrate and a second cover connected to the substrate, wherein the modular cover covers the substrate.

Abstract: A roof rail attachable to a roof of a motor vehicle includes a modular substrate connected to the roof, the modular substrate having a first portion connected by a first connection feature to a second portion. A cover is connected to the modular substrate and covers the modular substrate.

Abstract: A laminated light guide and component carrier includes a light guide of a light transmissive polymeric material. The light guide has a pocket in a first face. First electrical traces are printed on the first face. A light emitting diode is positioned in the pocket and supported on the light guide by attachment legs which extend outward from the pocket electrically connecting the light emitting diode to the first electrical traces. A light reflector is formed as a texturally modified area of the light guide directly aligned with the light emitting diode. A capacitive touch sensor is printed on a light guide second face and connected to second electrical traces defining capacitive touch traces printed on the second face. A window region of the light guide is defined where the capacitive touch sensor is aligned with the light reflector and the light emitting diode.

Abstract: A battery system for a vehicle includes a battery pack having a structure receiving at least one battery. Multiple sensors are mounted to the structure and sense operating conditions inside and outside of the structure. A safety module is disposed on the structure, the safety module having a centralized sensor processor processing signals received from the multiple sensors to identify if any of the operating conditions defines an abnormal condition of the structure. At least one battery pack sensor senses a condition within the battery pack and is in communication with a vehicle battery management system (BMS). The safety module is in communication with the BMS such that the condition within the battery pack is also communicated to the safety module. The centralized sensor processor identifies if the condition within the battery pack correlates with the abnormal condition of the structure.

Abstract: In the case of a battery support frame for an electric vehicle battery, said support frame being optimized in terms of tightness, compensation of component tolerances and load absorption in particular in the event of a crash, provision is made for a corner element to be arranged as tolerance compensation between a longitudinal profile and a transverse profile, the longitudinal profile and transverse profile being connected together via said corner element.

Abstract: A molded component assembly includes a printed circuit board with a first face and an oppositely facing second face. Multiple light emitting diodes are mounted on a first portion of the first face. Multiple electronics components are mounted on a second portion of the first face. A light guide of a light translucent polymeric material is positioned over the light emitting diodes and the electronic components. The light guide includes: a contact surface directly contacting the first portion of the first face except at locations of the light emitting diodes; a cavity created in the contact surface, the electronics components located within the cavity when the contact surface directly contacts the first portion of the first face; and a through hole extending through a body of the light guide and opening into the cavity.

Abstract: A component assembly includes a body having an electronics component mounted on a first face of the body. A light emitting diode is mounted on a first portion of the first face. A top plate is attached to the body and covers the light emitting diode and the electronics component. The top plate includes: a first cavity having the electronics component positioned within the first cavity; and a first support area homogeneously connected to the top plate and extending from the top plate to directly contact the body outside of the cavity to provide support for the top plate and to mitigate against collapse of the cavity.

Abstract: A laminated light guide and component carrier includes a polymeric material body having a first face. A light emitting diode is positioned on the first face. A connector is positioned on the first face. A through aperture is created in the body positioned proximate to the light emitting diode. A light guide of a light transmissive polymeric material is overmolded onto the first face proximate to and covering the light emitting diode and filling the through aperture, and omitted from the space envelope containing the connector. An opaque polymeric material coating layer is affixed onto the first face outside of the light guide.

Abstract: A molded component assembly includes a printed circuit board with a first face and an oppositely facing second face. Multiple light emitting diodes are mounted on a first portion of the first face. Multiple electronics components are mounted on a second portion of the first face. A light guide of a light translucent polymeric material has a contact surface, multiple light outlets, and multiple light emitting diode receiving pockets defining recesses in the contact surface, each sized to receive one of the light emitting diodes when the contact surface directly contacts the first portion of the first face, with visible light from the light emitting diodes transmitted through the light guide to the light outlets. A first polymeric material is molded over a portion of the second portion of the first face encapsulating the electronics components and contacting a portion of the light guide.

Abstract: A laminated printed circuit board with over-molded light guide includes a printed circuit board having electronic components mounted on a first face of the printed circuit board, and a bore extending through the printed circuit board. A light emitting diode is mounted on the first face proximate to the bore. An opaque film is fixed onto a second face of the printed circuit board, the opaque film creating an end wall of the bore. A light transmissive polymeric material is applied over each of the electronic components, the light emitting diode and a portion of the first face of the printed circuit board. A portion of the polymeric material extends into the bore and contacts the opaque film defining the end wall of the bore to create a light guide for transmitting light from the light emitting diode through the bore.

Abstract: In order to optimize a support frame for an electric vehicle battery in terms of tightness, compensation of component tolerances and load absorption in particular in the event of a crash, and to ensure good automated weldability, provision is made for a compensation insert to be arranged as tolerance compensation between a longitudinal profile and a transverse profile.