Abstract: A vehicle cargo construct including a floor having an upper surface and an oppositely opposed lower surface, a plurality of side wall panels extending from the floor, and an end wall panel extending from the floor between the plurality of side wall panels. Each of the plurality of side wall panels and end wall panel having an exterior surface and an oppositely opposed interior surface. Each of the floor, the plurality of side wall panels, and the end wall panel being formed of a composite sandwich panel material that includes a core defining a plurality of pores, a surface sheet adhered to a first face of the core by a first adhesive layer, and a structural skin adhered to a second face of the core by a second adhesive layer.

Abstract: A composite sandwich panel assembly with a defined set of breakpoints includes two or more open area cores, a high gloss surface sheet, and a structural skin. Each of the open area cores define a plurality of pores and each has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area cores 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 each of the open area cores by a second adhesive layer. The interface between each of the open area cores determines the breakpoint of the composite sandwich panel.

Abstract: A composite sandwich panel structure is provided with a lightweight core sandwiched between a high gloss surface sheet and an optically uniform painted or otherwise finished structural skin that are adhered to the lightweight core so as to reduce delamination of the formed part. The structural skin is surface finished during the formation of the sandwich panel structure and does not require any post manufacturing finishing steps such as a separate painting step or material application step. The sandwich composite structure, the high gloss surface sheet, and structural skin are adhered to the lightweight core with an adhesive or glue that is viscous when applied. The viscosity of the adhesive as applied allows for contact with the interior volume of the lightweight core to create more adhesion surface area yet without excessively running into the pores defined in the lightweight core before the adhesive cures or hardens.

Abstract: A battery containment construct including a first housing portion, a second housing portion complimentary to the first housing portion to define a cavity therebetween, and a fastening system to join the first housing portion to the second housing portion. The cavity defined therebetween being adapted to retain a plurality of reactive metal battery cells therein. The battery containment construct further including at least one fire department connection joined to at least one of the first housing portion or the second housing portion and in fluid communication with the cavity so enable connection of a fire hose to the battery containment construct for providing a fire inhibitor to the reactive metal battery cells in order to extinguish or contain a fire.

Abstract: A vehicle cargo construct including a floor, a plurality of side wall panels extending from the floor, and an end wall panel extending from the floor between the plurality of side wall panels. The floor has an exterior surface and an oppositely opposed interior surface. Each of the plurality of side wall panels has an exterior surface and an oppositely opposed interior surface. The has an exterior surface and an oppositely opposed interior surface. Each of the floor, the plurality of side wall panels, and the end wall panel are formed of a composite sandwich panel material formed including an open area core defining a plurality of pores disposed between a backing sheet and a surface sheet formed of a sheet molding composition (SMC) reinforced with unidirectional fibers.

Abstract: A vehicle component includes a body, a first beam, and a second beam. The body has a first fixture region and a second fixture region. The first beam is formed of a first composite material and has a first beam shape. The first beam is attached to the body and extends between the first fixture region and the second fixture region of the body. The second beam is formed of a second composite material and has a second beam shape that is simple compared to the first beam shape. The second beam is attached to the body and extends between the first fixture region and the second fixture region of the body.

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.

Abstract: A process is provided for thermal molding an article with at least one layer of thermoplastic fibers that are non-woven and uni-directionally oriented in combination with at least one layer of reinforcing fibers. The reinforcing fibers including glass, carbon, nature based, and combinations thereof; alone or mixed with chopped thermoplastic fibers. Upon subjecting the layers to sufficient heat to thermally bond in the presence of non-oriented filler fibers, thermoplastic fiber fusion encapsulates the filler fibers. The filler fibers impart physical properties to the resulting article and the residual unidirectional orientation of the thermoplastic melt imparts physical properties in the fiber direction to the article. By combining layers with varying orientations of uni-directional fibers relative to one another, the physical properties of the resulting article may be controlled and extended relative to conventional thermoplastic moldings.

Abstract: A vehicle removable panel system including a fixed vehicle structure and one or more removable panels configured to removably engage with the fixed vehicle structure. The vehicle removable panel system providing increased configurability, modularity, and functionality and being easily configurable by a single user without the use of tools. The vehicle removable panel system including a seal with moisture resistance and edges suitable for sealing the removable vehicle panels to other vehicle components including the fixed vehicle structure.

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 process is provided for thermal molding an article with at least one layer of thermoplastic fibers that are non-woven and uni-directionally oriented in combination with at least one layer of reinforcing fibers. The reinforcing fibers including glass, carbon, nature based, and combinations thereof; alone or mixed with chopped thermoplastic fibers. Upon subjecting the layers to sufficient heat to thermally bond in the presence of non-oriented filler fibers, thermoplastic fiber fusion encapsulates the filler fibers. The filler fibers impart physical properties to the resulting article and the residual unidirectional orientation of the thermoplastic melt imparts physical properties in the fiber direction to the article. By combining layers with varying orientations of uni-directional fibers relative to one another, the physical properties of the resulting article may be controlled and extended relative to conventional thermoplastic moldings.

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 releasable hinge assembly includes a mounting bracket, a hinge bracket, and at least one spring biased locking mechanism. The mounting bracket having a first mounting plate and two pin tabs extending therefrom, at least one of the pin tabs defining a through hole therein. The hinge bracket having a second mounting plate and a knuckle extending therefrom. The knuckle defining at least one cutout that is L-shaped. The at least one spring biased locking mechanism having a pawl arm and a pin. The at least one locking mechanism positioned within a channel of the hinge bracket with the pawl arm positioned within and projecting from the at least one cutout. The pawl arm configured to move within the at least one cutout to push the pin beyond a second end of the knuckle and through a through hole defined in the pin tab of the mounting bracket.

Abstract: A releasable hinge assembly includes a mounting bracket, a hinge bracket, and at least one spring biased locking mechanism. The mounting bracket having a first mounting plate and two pin tabs extending therefrom, at least one of the pin tabs defining a through hole therein. The hinge bracket having a second mounting plate and a knuckle extending therefrom. The knuckle defining at least one cutout that is being L-shaped. The at least one spring biased locking mechanism having a pawl arm and a pin. The at least one locking mechanism positioned within the a channel of the hinge bracket with the pawl arm positioned within and projecting from the at least one cutout. The pawl arm configured to move within the at least one cutout to push the pin beyond a second end of the knuckle and through a through hole defined in the pin tab of the mounting bracket.

Abstract: A process and system are provided for introducing chopped and dispersed carbon fibers on an automated production line amenable for inclusion in molding compositions, including the debundling of many carbon fibers collectively forming a tow into dispersed chopped carbon fibers that form a filler that undergoes plasma treatment prior to introducing coating silanes to uniformly increase bonding sites for coupling to a thermoset matrix. By exposing carbon tow to a plasma discharge, the carbon tow debundles and is used to form sheets of molding compositions with chopped dispersed fibers added to the composition, as the sheets move along a conveyor belt on the automated production line and at least one plasma generator mounted above the conveyor belt ionizes the carbon fibers. With resort to deionized air to mix plasma-treated chopped fibers, still further dispersion results.

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 method of building viscosity in a sheet molding composition is provided that includes a thickening agent of at least one of magnesium oxide, magnesium hydroxide, calcium oxide, calcium hydroxides, zinc oxide, borates, aluminum ion chelates, aluminum trihydrate, polyphosphate, epoxides being mixed into a phenolic resin liquid or solution that includes novolac resin. An initial viscosity results for the mixture. The viscosity builds from the initial viscosity to 36 hours, from 36 to 142 hours, and then from 142 hours to 176 hours to define a slope ratio of viscosities in these time ranges of 1.5-8:1:-0.4-2 and a having terminal viscosity as measured at 176 hours. Alternatively, the initial viscosity is between 500 and 50,000 centiPoise (cP) and at 24 hours thereafter builds to between 1 million to 50 million cP, and the terminal viscosity thereafter of between 10 million and 200 million cP.

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.