Abstract: A bumper assembly includes a retention member, a front-loaded component, and a bumper shell. The retention member includes a plurality of retaining features. The front-loaded component includes a plurality of receiving members. The bumper shell is positioned substantially between the retention member and the front-loaded component. The plurality of retaining features are coupled to the plurality of receiving members such that the retention member and the front-loaded component engage the bumper shell.

Abstract: The present disclosure relates to a hybrid material panel assembly for a vehicle. The panel assembly includes a panel and a plurality of mounting flanges integrally formed with the panel. The panel is formed of a first material having a first coefficient of thermal expansion. The plurality of mounting flanges are formed of a second material having a second coefficient of thermal expansion, where each of the plurality of mounting flanges include a mounting area that defines a mounting surface and at least one mounting hole. The first coefficient of thermal expansion is greater than the second coefficient of thermal expansion.

Abstract: A battery module includes a first side rail, a second side rail, one or more battery cell banks, and one or more battery cell separators. The one or more battery cell banks are positioned between the first side rail and the second side rail. The one or more battery cell separators are positioned within the one or more battery cell banks and configured to separate one or more battery cells positioned adjacent one another. The one or more battery cell separators include one or more cell barriers and a support structure. The one or more cell barriers are positioned adjacent the one or more battery cell banks. The support structure is positioned between the one or more cell barriers. The one or more battery cell separators are configured to propagate thermal energy produced from the one or more battery cells.

Abstract: An energy absorbing side rail including an inner rail, an outer rail fixedly coupled to the inner rail defining a cavity, the outer rail defining triggers extending along at least a portion of the outer rail, and at least one energy absorber housed in the cavity, wherein at least one energy absorber is positioned in-line with the triggers.

Abstract: A battery enclosure includes a tub defining an internal volume, a lid, a cross member within the internal volume, and a mounting bracket. The tub has a bottom and a wall integrally formed with the bottom. The lid is configured to couple to the wall to enclose the internal volume. The cross member is coupled to the tub. The mounting bracket is attached to the bottom of the tub and is configured to releasbly secure a battery.

Abstract: An automobile pedal release system that includes a housing having first and second side walls spaced apart by a cleft, where each side wall includes a pocket recessed into an inner surface such that the two pockets oppose one another; a brake pedal assembly having a pivot member disposed in the cleft and defining a pivot axis, first and second bushings, and a brake pedal arm rotatable about the pivot axis relative to the two bushings, where each busing is disposed in a first portion of one pocket and receives one of two ends of the pivot member; and a striker assembly having a striker and two plugs, the striker having an elongated body extending in the cleft between the side walls, where each plug is disposed in a second portion of one pocket and includes a bore that receives one of two ends of the striker.

Abstract: The present disclosure relates to a hybrid material panel assembly for a vehicle. The panel assembly includes a panel and a plurality of mounting flanges integrally formed with the panel. The panel is formed of a first material having a first coefficient of thermal expansion. The plurality of mounting flanges are formed of a second material having a second coefficient of thermal expansion, where each of the plurality of mounting flanges include a mounting area that defines a mounting surface and at least one mounting hole. The first coefficient of thermal expansion is greater than the second coefficient of thermal expansion.

Abstract: An automobile pedal release system that includes a housing having first and second side walls spaced apart by a cleft, where each side wall includes a pocket recessed into an inner surface such that the two pockets oppose one another; a brake pedal assembly having a pivot member disposed in the cleft and defining a pivot axis, first and second bushings, and a brake pedal arm rotatable about the pivot axis relative to the two bushings, where each busing is disposed in a first portion of one pocket and receives one of two ends of the pivot member; and a striker assembly having a striker and two plugs, the striker having an elongated body extending in the cleft between the side walls, where each plug is disposed in a second portion of one pocket and includes a bore that receives one of two ends of the striker.

Abstract: An automobile pedal release system that includes a housing having first and second side walls spaced apart by a cleft, where each side wall includes a pocket recessed into an inner surface such that the two pockets oppose one another; a brake pedal assembly having a pivot member disposed in the cleft and defining a pivot axis, first and second bushings, and a brake pedal arm rotatable about the pivot axis relative to the two bushings, where each busing is disposed in a first portion of one pocket and receives one of two ends of the pivot member; and a striker assembly having a striker and two plugs, the striker having an elongated body extending in the cleft between the side walls, where each plug is disposed in a second portion of one pocket and includes a bore that receives one of two ends of the striker.

Abstract: A method of assembling a vehicle door hinge that includes providing a first bracket comprising a single pivot arm extending transversely from a base of the first bracket, wherein a first pivot axis hole is disposed in the single pivot arm of the first bracket; providing a second bracket comprising a single pivot arm extending transversely from a base of the second bracket, wherein a cylindrical bearing of a pivot bushing is disposed in a second pivot axis hole disposed in the single pivot arm of the second bracket; and coupling a pivot pin to the pivot bushing and the first and second brackets to rotatably couple the first and second brackets together by press fitting a knurled cylindrical surface of the pivot pin with a receiving surface of the single pivot arm of the first bracket that defines the first pivot axis hole, wherein a shoulder of the pivot pin that is adjacent to the knurled cylindrical surface is disposed within a bore of the pivot pin and the second pivot axis hole.

Abstract: A method of manufacturing a tubular member for an automotive application that includes providing a flat workpiece of a material; forming at least one lance in the flat workpiece; roll-forming the flat workpiece into a tubular configuration; induction welding a seam of the tubular workpiece after the roll-forming; and trimming the tubular workpiece through the lance after welding the seam.

Abstract: A parking brake emulator assembly for a vehicle is provided. The emulator assembly includes a mounting bracket. The mounting bracket includes a front spring mounting flange with a spring mounting hole. The emulator assembly further includes a brake lever, a spring guiding rod, a spring, and a rear spring holder. The brake lever is rotatable relative to the mounting bracket into a neutral position and a brake application position. The spring guiding rod is coupled to the brake lever via a pinned connection, and extends through the spring and the rear spring holder. Rotation of the brake lever from the neutral position to the brake application position moves the pinned connection to thereby move the spring guiding rod and the rear spring holder towards the front spring mounting flange, thereby compressing the spring.

Abstract: A vehicle door hinge that includes a door bracket mountable to a vehicle door, a body bracket mountable to a vehicle body, a pivot bushing having a cylindrical bearing that is disposed within a pivot axis hole of the body bracket, and a pivot pin that rotatably couples the door bracket and the body bracket together. The pivot pin includes a first shoulder disposed within the cylindrical bearing; and the pivot pin includes a second shoulder extending from the first shoulder. The second shoulder has a knurled cylindrical surface that is disposed within a pivot axis hole of the door bracket.

Abstract: A method of manufacturing a tubular member for an automotive application that includes providing a flat workpiece of a material; forming at least one lance in the flat workpiece; roll-forming the flat workpiece into a tubular configuration; induction welding a seam of the tubular workpiece after the roll-forming; and trimming the tubular workpiece through the lance after welding the seam.

Abstract: A vehicle bumper assembly is provided having an energy absorber, a bracket, a step pad and a bumper fascia. The energy absorber includes an upper horizontal surface wherein the upper horizontal surface may define a deformable structure. The deformable structure may be in the form of flexible fins. The bracket may be mounted to the vehicle frame on a first end of the bracket and the energy absorber affixed to a second end of the bracket. The step pad may be affixed to the energy absorber. The bumper fascia may be affixed to either or both the step pad and the energy absorber.

Abstract: A vehicle bumper assembly is provided having an energy absorber, a bracket, a step pad and a bumper fascia. The energy absorber includes an upper horizontal surface wherein the upper horizontal surface may define a deformable structure. The deformable structure may be in the form of flexible fins. The bracket may be mounted to the vehicle frame on a first end of the bracket and the energy absorber affixed to a second end of the bracket. The step pad may be affixed to the energy absorber. The bumper fascia may be affixed to either or both the step pad and the energy absorber.

Abstract: A vehicle bumper assembly includes a polymeric support structure and a metal cover. The polymeric support structure may be one piece or a multi-piece component. The polymeric support structure includes a plurality of ribs formed on a substantially vertical wall. The chrome-plated metal cover is disposed on the one-piece polymeric support structure.