Abstract: A structural assembly includes a frame and a plurality of panels. The frame includes a wall that at least partially defines an interior region. The plurality of panels is disposed at least partially in the interior region and is coupled to the frame. The plurality of panels includes a first panel and a second panel. The first panel includes a first surface and a second surface opposite the first surface. The first surface defines a first plurality of depressions and the second surface defines a first plurality of protrusions complementary to the first plurality of depressions. The second panel includes a third surface and a fourth surface opposite the third surface. The third surface defines a second plurality of depressions. The fourth surface defines a second plurality of protrusions complementary to the first plurality of depressions. The first panel is coupled to the second panel.

Abstract: An serviceable battery pack and assembly method may include a battery pack having a stanchion extending through a wall of the battery pack, a first battery pack seal between the stanchion and the wall of the battery pack, attachment of the battery pack at the exterior of a floor pan of a vehicle at the stanchion, and a second battery pack seal between the exterior of the floor pan and the wall of the battery pack surrounding the stanchion.

Abstract: A battery enclosure, support beam for the battery enclosure and method of providing structural support to the battery enclosure. The battery enclosure includes a base having a first sidewall and a second sidewall opposite the first sidewall. The support beam extends from the first sidewall to the second sidewall. The support beam includes a body having a first beam end and a through passage. An internal stabilizer disposed within the through passage at the first beam end. The internal stabilizer includes a first stabilizer sidewall extending from a first stabilizer end to a second stabilizer end, a second stabilizer sidewall extending from the first stabilizer end to the second stabilizer end, and a bridge connecting the first stabilizer sidewall to the second stabilizer sidewall at the second stabilizer end.

Abstract: A structural assembly includes a frame and a plurality of panels. The frame includes a wall that at least partially defines an interior region. The plurality of panels is disposed at least partially in the interior region and is coupled to the frame. The plurality of panels includes a first panel and a second panel. The first panel includes a first surface and a second surface opposite the first surface. The first surface defines a first plurality of depressions and the second surface defines a first plurality of protrusions complementary to the first plurality of depressions. The second panel includes a third surface and a fourth surface opposite the third surface. The third surface defines a second plurality of depressions. The fourth surface defines a second plurality of protrusions complementary to the first plurality of depressions. The first panel is coupled to the second panel.

Abstract: Electric vehicle battery enclosures and methods of assembling electric vehicle battery enclosures involve a base portion to hold one or more batteries that provide motive power to an all-electric or hybrid electric vehicle. An electric vehicle battery enclosure includes a cover portion to mate with the base portion to enclose the one or more batteries, and a sealant to create a bond between the base portion and the cover portion around an entire perimeter of the enclosure and to seal the enclosure based on a uniform height of the sealant around the perimeter of the enclosure.

Abstract: A sheet metal assembly includes a drawn metal sheet constructed of a metal material. The drawn metal sheet defines a surface and includes one or more stiffening features disposed along the drawn metal sheet. The one or more stiffening features represents a raised area disposed along the surface of the drawn metal sheet. Each of the one or more stiffening features include a predefined draw depth ranging from about twenty millimeters to about eighty millimeters.

Abstract: A battery enclosure, support beam for a battery enclosure and method of manufacturing the support beam. The battery enclosure includes a base and the support beam is securable within the base. The support beam includes a body, a nut channel secured to the body, and a mechanical fastener attached to the nut channel. The nut channel is formed into a u-shaped channel. The mechanical fastener is attached to the nut channel and the nut channel is secured to the body of the support beam.

Abstract: A spacer and clip device includes a body including a clip portion and a spacer portion separated by a channel edge defining a channel extending longitudinally through the body, the clip portion and the spacer portion connected by a joining portion. The body includes an attachment edge defining an attachment opening that extends laterally through the body, the spacer portion establishes a standoff height, and the body is compressible to adjust the standoff height.

Abstract: A method of resistance spot welding a workpiece stack-up. The workpiece stack-up includes at least a steel workpiece and an aluminum workpiece. The method involves attaching a steel plate to the steel workpiece at a weld-site of the workpiece stack-up, passing electrical current between a first welding electrode and a second welding electrode at the weld-site, and terminating passage of electrical current between the first and second welding electrodes in order to form a weld joint. The steel plate serves to stiffen the weld joint.

Abstract: A spacer and clip device includes a body including a clip portion and a spacer portion separated by a channel edge defining a channel extending longitudinally through the body, the clip portion and the spacer portion connected by a joining portion. The body includes an attachment edge defining an attachment opening that extends laterally through the body, the spacer portion establishes a standoff height, and the body is compressible to adjust the standoff height.

Abstract: A battery enclosure, support beam for the battery enclosure and method of providing structural support to the battery enclosure. The battery enclosure includes a base having a first sidewall and a second sidewall opposite the first sidewall. The support beam extends from the first sidewall to the second sidewall. The support beam includes a body having a first beam end and a through passage. An internal stabilizer disposed within the through passage at the first beam end. The internal stabilizer includes a first stabilizer sidewall extending from a first stabilizer end to a second stabilizer end, a second stabilizer sidewall extending from the first stabilizer end to the second stabilizer end, and a bridge connecting the first stabilizer sidewall to the second stabilizer sidewall at the second stabilizer end.

Abstract: A battery enclosure, support beam for a battery enclosure and method of manufacturing the support beam. The battery enclosure includes a base and the support beam is securable within the base. The support beam includes a body, a nut channel secured to the body, and a mechanical fastener attached to the nut channel. The nut channel is formed into a u-shaped channel. The mechanical fastener is attached to the nut channel and the nut channel is secured to the body of the support beam.

Abstract: Electric vehicle battery enclosures and methods of assembling electric vehicle battery enclosures involve a base portion to hold one or more batteries that provide motive power to an all-electric or hybrid electric vehicle. An electric vehicle battery enclosure includes a cover portion to mate with the base portion to enclose the one or more batteries, and a sealant to create a bond between the base portion and the cover portion around an entire perimeter of the enclosure and to seal the enclosure based on a uniform height of the sealant around the perimeter of the enclosure.

Abstract: An serviceable battery pack and assembly method may include a battery pack having a stanchion extending through a wall of the battery pack, a first battery pack seal between the stanchion and the wall of the battery pack, attachment of the battery pack at the exterior of a floor pan of a vehicle at the stanchion, and a second battery pack seal between the exterior of the floor pan and the wall of the battery pack surrounding the stanchion.

Abstract: One aspect of the invention provides a system for treating wastestream, particularly a liquid or aqueous radwaste, for safe disposal and, in final processing, converting it into one or both forms including an aqueous form for safe discharge to the environment and a solidified form for safe disposal. Another aspect provides the capacity to employ a step where a specific target element strategy can be set up synchronizing sorbent substance choices and multiple recycle options to remove target substances from wastestream as a part of its Sorption or Powder Sorbent Isotopic Reduction step (II). Other steps cooperate with Sorption step (II) including Oxidation (I) to inactivate or destroy existing chelants, Solid-Liquid separation (III), and Selective Ion Exchange (IV) to deliver the wastestream to final processing.

Abstract: A method of resistance spot welding a workpiece stack-up. The workpiece stack-up includes at least a steel workpiece and an aluminum workpiece. The method involves attaching a steel plate to the steel workpiece at a weld-site of the workpiece stack-up, passing electrical current between a first welding electrode and a second welding electrode at the weld-site, and terminating passage of electrical current between the first and second welding electrodes in order to form a weld joint. The steel plate serves to stiffen the weld joint.

Abstract: A system and method for bonding structures includes a method of bonding a first panel to a second panel. An adhesive material is applied to at least one of the first panel and the second panel and is disposed between the first panel and the second panel. A welding device having at least a first electrode and a second electrode is configured to receive and position the first panel and second panel between the first and second electrodes. The welding device generates an electric current with the first and second electrodes to apply to the first panel and the second panel. The electric current generates thermal energy having a first temperature that cures the adhesive material positioned between the first and second electrodes to bond the first panel with the second panel.

Abstract: A multi-channel seat mounting wire retention bracket for a vehicle subjectable to an external force event and including a body structure and a seat having a seat mounting wire includes a body structure attachment portion and a wire retention portion. The body structure attachment portion is attachable to the body structure. The wire retention portion is configured to form a wire installation channel and a wire catch channel. The wire installation channel is configured to receive and retain the seat mounting wire when the seat is installed in the vehicle and to allow removal of the seat mounting wire when the seat is removed from the vehicle. The wire catch channel is configured to receive and retain the seat mounting wire during the external force event.

Abstract: A tether hook bracket for a vehicle subjectable to an external force event, followed by a rebound event, and having a body structure and a child seat connectable to the body structure via a tether having a tether hook includes a body structure attachment portion, a tether hook connection portion, and a tether hook rebound blocker portion. The body structure attachment portion is configured to be attachable to the body structure. The tether hook connection portion is configured to receive the tether hook, such that the tether hook is connected to the tether hook bracket. The tether hook rebound blocker portion is disposed between the body structure attachment portion and the tether hook connection portion and is configured to maintain the connection of the tether hook to the tether hook bracket when the vehicle is subjected to the rebound event.

Abstract: A tether hook bracket for a vehicle subjectable to an external force event, followed by a rebound event, and having a body structure and a child seat connectable to the body structure via a tether having a tether hook includes a body structure attachment portion, a tether hook connection portion, and a tether hook rebound blocker portion. The body structure attachment portion is configured to be attachable to the body structure. The tether hook connection portion is configured to receive the tether hook, such that the tether hook is connected to the tether hook bracket. The tether hook rebound blocker portion is disposed between the body structure attachment portion and the tether hook connection portion and is configured to maintain the connection of the tether hook to the tether hook bracket when the vehicle is subjected to the rebound event.