Abstract: A high strength frame of a sealable containment system is provided for containing and protecting energy cells or batteries. The protection provided by the high strength frame provides impalement resistance, impact resistance, fire resistance, and fluid penetration prevention. The frame includes a shock structure/energy absorber to protect the battery from forces during potential impacts with other vehicles or objects. The frame of a battery containment system is further designed to resist impalements in order to protect the batteries. Furthermore, because vehicle batteries are prone to extreme fire in the event of an impact or impalement, the containment system provides a sealed battery environment to keep fluid and moisture out during normal operation and to limit oxygen in the event of a battery fire.

Abstract: A system and method for dielectric bonding including a dielectric heater having a pair of opposing electrode plates, a nest removably coupled to a first electrode plate of the pair of electrode plates, and an interchangeable electrode assembly removably coupled to a second electrode plate of the pair of electrode plates. The nest having a plurality of cooling channels defined in a body thereof in which a cooling fluid circulates to cool a material assembly that is supported by the nest. The interchangeable electrode assembly having a plurality of concentrator members that are configured to concentrate energy from a voltage source in predetermined locations on the material assembly.

Abstract: Provided is a vehicle structure disposed at a lower portion of a center of a vehicle body, the vehicle structure including: a battery cover, a battery tray, and a structural member A for absorbing impact energy. Each of the battery cover and the battery tray is configured with an integrally molded fiber-reinforced plastic. The structural member A is located outside in a vehicle width direction of at least the battery cover and the battery tray. The structural member A is fastened together with the battery cover and the battery tray.

Abstract: A vehicle removable roof system including a roof support structure removably attachable to a vehicle, the roof support structure including a plurality of vertically oriented supports and at least one horizontally oriented support. The at least one removable panel configured to engage with the roof support structure. The vehicle removable roof system formed of a light weight sandwich composite structure that affords a high gloss surface without resort to additional processing after production with improved moisture resistance and edges suitable for sealing the removable roof assembly to other vehicle components.

Abstract: A tool for manufacturing a sandwich composite material component is provided that includes a lower tool having a surface configured to receive materials for forming the sandwich composite material component. An upper tool is also provided that has a sealing edge and a cutting edge. The upper tool and the lower tool are configured to be separated to an open position and to be brought together to a closed position, the upper tool and the lower tool define a cavity when in the closed position. A process for forming a sandwich composite material component is also provided.

Abstract: A vehicle structure includes a battery tray disposed at a lower portion of a center of a vehicle body, and a cross member extending in a vehicle width direction and inserted into the battery tray. The battery tray includes a first bottom portion, a peripheral wall erected on an outer periphery of the first bottom portion, a first inner wall connected to the first bottom portion, a second inner wall connected to the first bottom portion, and a second bottom portion connected to both the first inner wall and the second inner wall and raised from the first bottom portion, which are configured with an integrally molded fiber-reinforced plastic. A recessed portion extending in the vehicle width direction is formed by the first inner wall, the second inner wall, and the second bottom portion. The cross member is inserted into at least one location of the recessed portion.

Abstract: A battery tray for mounting a battery for driving a vehicle includes a bottom; a peripheral wall erected on an outer circumference of the bottom; a flange connected to a top of the peripheral wall and extending outwards of the peripheral wall; a first inner wall connected to the bottom, a bending angle between the first inner wall and the bottom being between 90 degrees and 135 degrees; a second inner wall connected to the bottom, a bending angle between the second inner wall and the bottom being between 90 degrees and 135 degrees; and a stud bolt pedestal connected to both the first inner wall and the second inner wall and provided above the bottom. The bottom, the peripheral wall, the flange, the first inner wall, the second inner wall, and the stud bolt pedestal being integrally molded from fiber reinforced plastics containing discontinuous fibers.

Abstract: A vehicle component unit including a reinforcing open area core layer, a high gloss surface layer, and an encapsulating plastic layer. The reinforcing open area core layer has a first side and an oppositely opposed second side and a first end and an oppositely opposed second end each extending between the first side and the second side. The high gloss surface layer is positioned on the first side of the reinforcing open area core layer. The encapsulating plastic layer has a first end and a second end and is positioned on the second side of the reinforcing open are core layer. The first end and the second end of the encapsulating plastic layer are embedded into the high gloss surface layer with an embedded length L, such that the encapsulating plastic layer covers the first end and the second end of the reinforcing open area core layer.

Abstract: A vehicle removable roof system including a fixed vehicle structure, one or more removable panels configured to engage with the fixed vehicle structure, and a water management system positioned between the one or more removable panels and the fixed vehicle structure. The removable panels may be formed of a composite sandwich panel assembly, which may include an open area core defining pores, a high gloss surface sheet adhered to a first face of the open area core by a first adhesive layer, and a structural skin adhered to a second side of the open area core by a second adhesive layer. The removable panels are configured for installation to and removal from the fixed vehicle structure by a single user and without the use of tools.

Abstract: A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.

Abstract: A system and method for dielectric bonding including a dielectric heater having a pair of opposing electrode plates, a nest removably coupled to a first electrode plate of the pair of electrode plates, and an interchangeable electrode assembly removably coupled to a second electrode plate of the pair of electrode plates. The nest having a plurality of cooling channels defined in a body thereof in which a cooling fluid circulates to cool a material assembly that is supported by the nest. The interchangeable electrode assembly having a plurality of concentrator members that are configured to concentrate energy from a voltage source in predetermined locations on the material assembly.

Abstract: A high strength, light weight battery containment construct for containing and protecting energy cells and providing impact, fire, and fluid penetration resistance includes a first housing portion, a second housing portion, and a joiner clip configured to hold the first housing portion and second housing portion together. The first housing portion has a first body and a first flange extending from the first body. The second housing portion has a second body and a second flange extending from the second body. The second flange is configured to engage the first flange such that the first body of the first housing portion and the second body of the second housing portion define a cavity therebetween. The joiner clip is configured with a C-shaped cross section to engage the first flange and the second flange to join the first housing portion to the second housing portion.

Abstract: A vehicle component construct including a panel formed of a composite sandwich material. The composite sandwich material including an open area core defining a plurality of pores, a high gloss surface sheet adhered to a first face of the open area core by a first adhesive layer, and a structural skin adhered to a second face of the open area core by a second adhesive layer. The exterior surface of the panel being defined by the high gloss surface sheet of the composite sandwich panel material and the oppositely opposed interior surface of the panel being defined by the structural skin of the composite sandwich material. The vehicle component construct being suitable for use as a body section of a vehicle.

Abstract: A vehicle component construct and process of making the same including a frame formed of a composite sandwich panel material and a window formed of a transparent resin within the frame. The composite sandwich panel material of the frame including an open area core defining a plurality of pores, a high gloss surface sheet adhered to a first face of the open area core by a first adhesive layer, and a structural skin adhered to a second face of the open area core by a second adhesive layer. The frame defining a through opening that extends from an exterior surface of the frame to an oppositely opposed interior surface of the frame. The window being formed within the through opening of the frame.

Abstract: A puncture resistant shield is provided for use with a battery containment system that is light weight and resistant to corrosion, while improving the safety performance of the battery containment system by providing greater impact and impalement protection as compared to conventional vehicle components. The puncture resistant shield also has utility in that it may be used with existing battery containment systems as an aftermarket installation to increase protection of the batteries contained therein or may be designed for use with new manufactured battery containment systems.

Abstract: A battery containment construct is provided that includes a unitary tray having a bottom and a set of walls including a first side wall, a second side wall, a first end wall, and a second end wall. The set of walls extending from the bottom of the tray and defining a cavity within the tray. A cover removably attached to the plurality of walls of said tray opposite the bottom of said tray. Energy absorption components attached to the bottom of the tray external to at least one of the set of walls in some versions to enhance impact resistance. The construct has high strength, is light weight and well suited for containing and protecting energy cells or batteries that adjusted to impact resistance, fire resistance, and fluid penetration prevention.

Abstract: A vehicle removable roof system including a roof support structure removably attachable to a vehicle, the roof support structure including a plurality of vertically oriented supports and at least one horizontally oriented support. The at least one removable panel configured to engage with the roof support structure. The vehicle removable roof system formed of a light weight sandwich composite structure that affords a high gloss surface without resort to additional processing after production with improved moisture resistance and edges suitable for sealing the removable roof assembly to other vehicle components.

Abstract: A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.

Abstract: A high strength frame of a sealable containment system is provided for containing and protecting energy cells or batteries. The protection provided by the high strength frame provides impalement resistance, impact resistance, fire resistance, and fluid penetration prevention. The frame includes a shock structure/energy absorber to protect the battery from forces during potential impacts with other vehicles or objects. The frame of a battery containment system is further designed to resist impalements in order to protect the batteries. Furthermore, because vehicle batteries are prone to extreme fire in the event of an impact or impalement, the containment system provides a sealed battery environment to keep fluid and moisture out during normal operation and to limit oxygen in the event of a battery fire.

Abstract: A battery containment system is provided that includes a unitary battery tray having a bottom and walls that from the bottom of said tray and defining a cavity within the tray. A cover is includes having a cover body portion and a first flange extending from the cover body portion, the cover body portion configured to overlie the cavity within the tray and the walls of the tray, the first flange of said cover configured to extend beyond the walls of the tray. A shield having a shield body portion and a second flange extending from the shield body portion, the shield body portion is configured to underlie the bottom of the tray, the second flange of the shield is configured to extend beyond the bottom of the tray and configured to engage the first flange of the cover.