Abstract: A liftgate cargo module having an integrated tailgate that unfolds from a hatch or liftgate of a vehicle that adds additional storage and provides a cargo load floor. When unfolded, there is an integrated pass through door formed in the hatch or liftgate permitting longer items to be hauled, while keeping the hatch or liftgate completely closed. The integrated tailgate includes an integrated tailgate taillight that indicates when the vehicle is braking or backing up. The integrated tailgate taillight also helps to show that the integrated tailgate is folded down from and extending from the hatch or liftgate of the vehicle. The integrated tailgate also includes integrated anchor points formed on the cargo load floor so items may be tied down and secured. An all-weather enclosure that is connectable to the cargo load floor for enclosing contents that are being hauled on the integrated tailgate may also be provided.

Abstract: The invention provides a hot stamped structural component (20) for an automotive vehicle, such as a B-pillar, including a first part (22) formed of a high strength steel material joined to a second part (24) formed of a high ductility steel material. The structural component (20) also includes a locally tempered transition zone (26) along the joint (28) to reduce the potential for failure along the joint (28). The transition zone (26) has strength and ductility levels between the strength and ductility levels of the remaining portions of the first and second parts (22, 24). The tempering step can be incorporated into a laser trimming cell or assembly cell, and thus the transition zone (26) can be created without adding an additional process step or increasing cycle time.

Abstract: An active grille shutter arrangement having a modular frame. The active grille shutter arrangement includes a primary frame piece defining a width and height of an aperture of the modular frame, wherein in the primary frame piece has a motor housing, and upper frame portion having a first end and a second end, a lower frame portion having a first end and a second end and the motor housing extends between the upper frame portion and the lower frame portion. There is a plurality of secondary frame pieces. The modular frame of the active grille shutter arrangement is formed by the connection of the primary frame piece in the secondary frame piece, wherein the modular frame defines the aperture.

Abstract: A method of manufacturing a hollow structural frame rail includes rotating a tube relative to a tool to reduce an outside diameter of the tube at predetermined positions along the length of the tube. An elastomeric insert is positioned within the tube. The tube is bent at a location containing the insert. The bent tube is hydroformed to define a finished shape of the frame rail.

Abstract: A method of resistive implant welding carbon fiber thermoplastic composites which includes providing at least two portions of a component formed with carbon fiber material, the at least two portions of the component each have a welding surface where the at least two portions of the component are welded together. One or more conductors of copper or aluminum mesh material positioned between the welding surface of the two portions. The method includes a forming tool having at least two portions capable of moving between an open position and a closed position. The forming tool has a welding region with non-conductive metal surface areas where electric current is selectively applied to facilitate the welding together of the at least two portions of the component. The forming tool has forming regions with conductive surfaces where the two components are shaped.

Abstract: End of arm tooling system and a method for manufacture is provided. The end or arm tooling system provides automated material handling, part manipulation, preforming and transferring of a pre-impregnated carbon fiber material. A robot is connected to end of arm tooling for automated material handling and transfer operations from at least a lower preform tool system where light compression is applied to a molding press. The end or arm tooling system includes a cured silicone membrane as well as vacuum and air blow off, allowing for robotically preforming, picking up and dropping-off pre-impregnated carbon fiber materials which are notoriously sticky and difficult to handle.

Abstract: A trim retainer assembly having a clip portion with a base and a molded housing having a keyhole and an opening. The keyhole in the doghouse is smooth for improved molding and elimination of tuning since there are no detents in the bore to tune or maintain. The base is provided with a pair of arms that are flexible and each arm having a self detent feature that passes through the opening in the housing to provide clip retention and, at the same time, float for tolerance variations is provided. The pair of arms also include nominal centering detents. The keyhole bore, opening, and clip portion provides clip detent, consistent retention effort, float, centering and anti-rotation.

Abstract: A system for mounting and supporting photovoltaic (PV) modules includes a frame rail that is formed with a longitudinally extending channel for retaining a plurality of mounting clips, and mounting clamps for anchoring the frame rail to a support base or support structure. Each mounting clamp includes a pair of jaws for engaging along a base portion of the fame rail. The mounting clips are arranged along the length of the frame rail, and are used to support the PV modules adjacent to the frame rails. Module clamps are used to hold the PV modules in place, the module clamps being secured to the mounting clips using elongated fasteners having an engaging end for engaging the mounting clip. The mounting clamps allow the frame rail position to be adjusted in two directions, and the mounting clips facilitate rapid mounting of the PV modules to the frame rail structure.

Abstract: A push on doghouse retainer arrangement used for providing a connection between the B-pillar of an automobile, and an appliqué having a high-gloss surface, or “show surface.” The a push on doghouse includes a formed low profile spring steel base and a slightly raised low profile doghouse portion, which includes a slot for receiving a base of a clip portion. The base also includes at least one attachment aperture. The attachment aperture includes an effective amount of serrations for holding of the doghouse onto a low profile rib molded into the part. The present invention simplifies mold design, minimizes potential for a read condition, and provides a robust engagement for a winged clip type fastener in limited space.

Abstract: Running board assembly for a motor vehicle having a passenger cab and a box. The running board assembly includes a linear actuator assembly partly disposed within a housing assembly, a running board operably coupled to the linear actuator assembly and movable relative to the housing assembly between a stowed position tucked underneath the vehicle, a cab entry position generally outwardly from the vehicle to support a user entering or exiting the passenger cab, and a box side step disposed generally outwardly from the vehicle and rearward of the cab entry position to provide a user with side access to the box, and a motor operably coupled to the linear actuator assembly for driving the linear actuator assembly in opposing first and second directions. The linear actuator assembly converts rotary input to linear motion to cause a drive arm having a linkage assembly to move the running board between the positions.

Abstract: The present invention is directed to a carrier for an automobile with integrated active ducting. The carrier includes at least one aperture, and at least one louver rotatably mounted in the aperture. Also attached to the carrier is an actuator, and the actuator is connected to the louver. The actuator is operable for moving the louver between an open position and a closed position such that when the louver is in the open position, air flow passes through the aperture.

Abstract: A frame rail for a vehicle has a pair of elongated structural members, each one of the pair of elongated structural members having flanges protruding from lateral edges thereof. The flanges of one of the pair of elongated structural members extend in a direction toward the flanges of the other one of the pair of elongated structural members. The frame rail also has first and second metallic web panels interconnecting the pair of elongated structural members. Overall, the frame rail has a box beam structure, wherein at least a major portion of each one of the first and second metallic web panels has a material thickness that is less than a material thickness of at least a major portion of each one of the pair of elongated structural members.

Abstract: A method of making a part is provided. A blank is loaded into a die assembly having a pair of shoes with forming pieces attached thereto and compressible members sandwiched between the shoes and the forming pieces. The die is closed about the blank to deform the blank into a part. The die is then opened by a predetermined distance while at least one of the compressible members deforms elastically to maintain contact between at least one of the forming pieces and the part. Less than the entire surface of the part is then conductively cooled through the at least one forming piece to provide a predetermined portion of the part with a predetermined microstructure.

Abstract: An active bed cover system having at least one deployable panel and at least one actuator. The deployable panel extends and retracts based on vehicle requirements and provides reduction in vehicle drag, thereby reducing emissions and improving fuel economy. Additionally, it allows for the system to retract within the tailgate and/or cargo bed liner allowing for access to the bed and improved usability and aesthetics. The active bed cover provides a fully deployable system with object detection, declutching of the actuator to help prevent damage, and communication with the vehicle to determine proper deployment and function.

Abstract: A hollow vane structure for an active grille system 100 having a first piece 12 of the vane body 10 that includes a front side 14 and a back side 16. The first piece 12 has a concave cross-section extending from the front side 14 toward the back side 16. This concave section creates a hollowed inward section 18 on the back side 16 of the first piece 12. The first piece 12 also includes an edge surface 20 formed on the first piece which defines a perimeter of the hollowed inward section 18. A second piece 22 of the vane body is connected to the back side 16 of the first piece 12 and extends across the hollowed inward section 18 and is connected to the first piece 12 to at least the edge surface 20 on the back side 16 of the first piece 12.

Abstract: A carrier for an automobile with integrated active ducting, and a method of making a louver therefor. The carrier includes at least one aperture, and at least one louver rotatably mounted in the aperture. Also attached to the carrier is an actuator, and the actuator is connected to the louver. The actuator is operable for moving the louver between an open position and a closed position such that when the louver is in the open position, air flow passes through the aperture.

Abstract: End of arm tooling system and a method for manufacture is provided. The end or arm tooling system provides automated material handling, part manipulation, pre-forming and transferring of a pre-impregnated carbon fiber material. A robot is connected to end of arm tooling for automated material handling and transfer operations from at least a lower preform tool system where light compression is applied to a molding press. The end or arm tooling system includes a cured silicone membrane as well as vacuum and air blow off, allowing for robotically preforming, picking up and dropping-off pre-impregnated carbon fiber materials which are notoriously sticky and difficult to handle.

Abstract: A fail safe module for an active grille having two or more vanes movable between an open position and a closed position. In the event of failure of an electrically driven actuator, a fail safe module connected between a driven vane of the two or more vanes and the electrically driven actuator moves the vanes to a fail-safe position. The fail safe module has a locked and unlocked position. When the fail safe module is in the locked position the fail safe module, the electrically driven actuator and the two or more vanes move together in response to the power provided by the electrically driven actuator. When the fail safe module is in the unlocked position, the fail safe module disengages the two or more vanes from the electrically driven actuator and moves the two or more vanes to the fail-safe position.

Abstract: A bumper assembly includes a bumper beam for absorbing an impact of a vehicle and a crash box attached to the bumper beam and extending along an axis A. A mounting plate is attached to the crash box and defines at least one lateral slot extending laterally along the mounting plate in spaced and perpendicular relationship to the axis A. A fastener extends through the lateral slot for mating with a mounting surface of the vehicle frame to establish a secured position of the bumper assembly. The fastener includes a shoulder disposed in abutting relationship with the mounting surface in the secured position to dispose the mounting plate and the mounting surface in spaced relationship to one another for allowing the fastener to slide laterally along the lateral slot during a vehicle impact to reduce the transfer of lateral impact forces from the bumper assembly to the vehicle frame.

Abstract: An apparatus for forming a three-dimensional (3D) object includes a 3D printing head, for fabricating a first portion of the 3D object by forming a plurality of successive layers of a first material. The apparatus also includes a delivery head for fabricating a second portion of the 3D object by dispensing onto the first portion of the 3D object a plurality of layers of a continuous-fiber reinforced second material. Further, the delivery head includes comprising a roller for pressing the continuous-fiber rein-forced second material into place during the dispensing thereof. A controller controls the 3D printing head and the delivery head to cooperatively form the 3D object, based on a dataset corresponding to a 3D object model.