Abstract: A vehicle panel arrangement having an inner panel having strategically positioned load point areas. Each of these load point areas includes a local reinforcement which is connected securely to the outer surface of the inner panel. The arrangement further includes bulkheads extending from the outside surface of the inner panel and a continuous reinforcement in contact with at least two locations on a vehicle body structure. The combination of the local reinforcements, bulkheads and continuous reinforcement ensures that when external forces are applied to the vehicle panel arrangement, the forces are efficiently distributed across the vehicle panel arrangement and to the vehicle body structure through the continuous reinforcement.

Abstract: A molded panel that encompasses all forward surfaces of a vehicle. The molded panel extends from the forward edge from a driver side front wheel opening, laterally across the front of the vehicle and terminating at a forward edge of a passenger side wheel opening. The molded panel extends in the vertical direction (i.e., perpendicular to the longitudinal axis of the vehicle) from a forward lower edge of a front valance up to a leading edge of one of a hood, a flunk, and a windshield of the vehicle. The molded panel further includes connection flanges formed on a back side surface for connection to a vehicle frame that does not have a front end module and front frame bulk head.

Abstract: A kinematic linkage assembly for an active grille shutter system having a frame connectable to a vehicle and forming an aperture. A kinematic linkage assembly with a plurality of vanes each moveable between an open position, an intermediate position, and a closed position. The rotation force from an actuator is transmitted across the first vane of the plurality of vanes to the first link at the first connection.

Abstract: The present invention includes a foldable step assembly for a vehicle. The step assembly includes a linkage arrangement for connection to a vehicle and articulating a step assembly from a deployed position to a stowed position. A drive mechanism is positioned remotely from the step assembly and is operatively in communication with the linkage arrangement for articulating said step assembly between the deployed position to the stowed position.

Abstract: A kinematic linkage assembly for a vehicle active grille shutter system. The kinematic linkage assembly includes a kinematic end cap with a driven gear and one or more driven gears connected to the driven gear. The driven gear includes a driven portion connected to an actuator. A gear portion of the driven gear circumscribes the driven portion. When a drive vane is engaged to the drive gear the gear portion and drive vane will rotate together. If the driven vane is missing the driven vane will rotate independently of the gear portion and none of the vanes of the assembly will be driven by the actuator.

Abstract: A roof panel module for a vehicle that includes a frame of the roof panel module connectable to a vehicle. The frame includes an opening that extends between an inside surface and outside surface of the frame. The frame further includes an inner piece having a plurality of inner flanges and an outside piece having a plurality of outside flanges which allows bonding of one of the plurality of inner flanges to one of the plurality of outer flanges. The roof panel module further includes a window extending across the opening on the outside surface of the frame that provides a viewing surface through a roof panel module of a vehicle. Connected to the frame is a light emission unit positioned within the opening of the frame. The light emission unit selectively emits light away from the inside surface of the frame and selectively emits light away from the outside surface of the frame.

Abstract: A liftgate formed with a thermoplastic which is overmolded around preselected reinforcements at stress points, such as a corner area, which includes a pair of separate reinforcement plates and wherein a 3-dimensional reinforcement plate is connected between the pair of separate reinforcements. Preferably the 3-dimensional reinforcement plate is connected to three reinforcements.

Abstract: A vehicle lighting assembly includes a solid state light emitter mounted on a first side of a substrate. A second side of the substrate is connected or adjacent to a heatsink. The heatsink may have a lower thermal conductivity than the second side of the substrate. A blower fluidly engages with the heatsink to flow fluid, e.g., air, through passages in the heatsink. The heatsink can include at least one aperture such that the moving fluid from the blower contacts at least a portion of the second side of the substrate.

Abstract: A system for assembling a vehicular window assembly includes a heating device that, when electrically operated, heats an electrical connector disposed at a glass panel of a vehicular window assembly to heat and melt solder disposed between the electrical connector and an electrically conductive trace established at the glass panel to form a solder joint providing electrically-conductive connection between the electrical connector and the electrically conductive trace established at the glass panel. A temperature sensor captures sensor data indicative of a temperature of the electrical connector and the solder. The system, based on processing at an electronic control unit (ECU) of the captured sensor data, adjusts electrical operation of the heating device to adjust the temperature of the electrical connector and the solder during the soldering process that forms the solder joint.

Abstract: A process for fiberglass recovered from recycling of windmill or similar products at the end of lifecycle converted into a non-woven fiberglass mat and applying predetermined sizing. Sizing is applied to this fiberglass mat by spraying silane sizing on both sides of the mat. Recycled fiberglass content can be operably varied. Polyurethane resin can be sprayed onto either the recycled non-woven fiberglass mat alone or on a combination of recycled fiberglass mat and virgin fiberglass mat. This resin-impregnated mat is then placed onto a heated tool in a compression molding machine. Exemplary application of the recycled glass fiber mat is in electric vehicle composite battery cover and plug-in hybrid electric vehicle composite battery cover.

Abstract: A tool head assembly for crimping, the assembly including an internal cam that spins freely on a stationary shaft in one direction and locks onto the shaft in the other direction. That cam rotates against the moving slide forcing to move away from the stationary shaft opening a gap between rollers. A controller is programmed to have the drive rotate in one direction for a set time period, then reverse the rotation to begin the crimp process. The start rotation of the drive rotates the cam and opens the roller gap. The forward rotation allows the cam to swing, closing the gap and rotating the rollers around a seal. The tool eliminates the air cylinder and related pneumatic hoses and valve making the head smaller and allows a controller to communicate with any OEM production system to verify the tool has been used and was used correctly.

Abstract: An injection molded slide actuator assembly which has a frame, a slide carrier and a slide track member. The injection molded slide actuator has an X, Y, and Z axis with the slide track member having at least one track slot extending along the y and the Z direction and said slide carrier having at least one cooperating outwardly extending side members for engaging the at least one track slot.

Abstract: Co-molding of non-crimped fabric and sheet molding composition. The pre-preg of non-crimped fabric is dried to achieve suitable stiffness for molding. The pre-preg allows the pre-formed non-crimped fabric feature to retain its shape during molding. A plurality of thorns is provided in the molding tooling to further prevent movement of pre-preg during molding. The method of co-molding includes, drying of the pre-preg to achieve suitable stiffness for molding, pre-forming of the pre-preg, and incorporating a plurality of stand-off features or thorns in the molding tool to prevent movement of pre-preg during co-molding so that predetermined full coverage of non-crimped fabric is maintained in predetermined area(s) of the molded part and the continuous fibers of the non-crimped fabric are not distorted.

Abstract: A seamless lighting arrangement for a vehicle panel. The vehicle panel has an inside surface and an outside surface. The vehicle panel has a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel. Connected to the inside surface of the vehicle panel is a bracket. The seamless lighting arrangement further includes a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel. The lens further includes a light unit fixedly connected to the lens. The light unit has a projector port for emitting light from a light source. The light transmission portion of the lens has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens.

Abstract: A one-piece linkage assembly (20) includes a linkage base (120, 122, 22) for securement to a structure and a linkage follower (124, 24) fixed to the linkage base (120, 122, 22) with a stainless steel first pivot pin in a hinged configuration. The linkage base (120, 122, 22) and the linkage follower (124, 24) each are made of a molded material, such as plastic, and are formed together with the first metal pivot pin (126, 130, 132, 136, 26, 32, 36) insert molded there between. A linkage coupler (130, 30) and a linkage drive (134, 34) are similarly pivotably secured to the linkage follower (124, 24) in a chained configuration and are also made of the molded material and are formed together with the linkage base (120, 122, 22) and the linkage follower (124, 24), with additional stainless steel pivot pins insert molded between the linkage follower (124, 24) and the linkage coupler (130, 30) and between the linkage coupler (130, 30) and the linkage drive (134, 34).

Abstract: A composite liftgate system with an inner panel construction having a strengthening channel structure. Structural composite reinforcements are bonded to the inner panel where additional strength is needed to meet predetermined performance requirements. Where the extra structure is needed, no steel or a minimum amounts of steel is used and the structural reinforcements are bonded in place using adhesive prior to application of additional fasteners.

Abstract: Provided is a removable cover (10) for the trailer hitch area of a vehicle such as an SUV, pickup truck or other vehicle (11). A fascia (12) having an opening (14) for allowing access for a trailer hitch area of a vehicle is provided. A cover member (16) for removably covering the opening (14) is operative for being secured in the opening (14). The cover member includes a lock mechanism for being received in the fascia, said lock mechanism including a depressible button release mechanism (18).

Abstract: Typical active grille shutter vanes meet the frame at either end, with a small clearance between the parts, to avoid the parts binding together. This invention adds a set of soft flaps, which are molded in a two-shot process, to allow the vanes to seal against the frame while closed but sit free of the frame while open. This clearance is accomplished by adding a stepped wall to the frame component, to create an interference between the vane flaps while turning to the closed position, causing the flaps to be deflected in a gradual manner, so the actuator motor is not taxed with a sudden increase in required torque.

Abstract: A liftgate integrating bulkhead reinforcements into an inner panel and/or outer panel of the liftgate or closure creating an efficient design that adds mold-in reinforcement structure and eliminates the need to add steel or plastic parts to meet performance requirements.