Abstract: A solar cell base layer surrounded by a layer of protective material that has a softening temperature which is useable in post processing of the solar cell in a thermoforming environment.

Abstract: A weather resistant autonomous driving sensor unit for an autonomous vehicle driving system. The sensor unit further includes a cover having an inside surface facing the one or more light detection and ranging sensors, and an external surface facing an external environment of a vehicle. The cover is formed of molded polycarbonate and also forms a vehicle component selected from the group consisting of a vehicle grille, bumper and front end module. A hydrophilic coating applied to the external surface of the coating. The hydrophilic coating can be made of several different compounds that are applied to the external surface using spraying, dipping or vapor deposition. The hydrophilic coating selected must provide a droplet thickness to diameter ratio of less than 0.3 when the water contact angle on the external surface of the cover is less than 40 degrees or between about 25 degrees to about 40 degrees.

Abstract: A rain simulation system that replicates realistic raindrop characteristics for controlled testing is invented. The rain simulation system can be used as a stand-alone system with wind using a blower fan or in a wind tunnel, and without wind to create wind-driven and vertically falling rain droplets, respectively. In addition, methods to simulate rainfall for stationary and moving objects such as a road passenger vehicle are proposed. The rain simulation system is fully adjustable for a range of droplet size, impact velocity, rain intensity, rain coverage via the use of dripping nozzle devices and positioning of system components. The rain simulation system dispenses distinct droplets or continuous streams that can be broken down into droplets by wind. A rain nozzle device is coupled with a rain reservoir, and multiple nozzles are used to create a rain matrix, the full matrix is integrated with a rain rack and rainwater flow control strategy.

Abstract: A method of injection molding of a class A surface part comprising the steps of first providing a first injections mold cavity for forming a part geometry and a second injection mold cavity for molding of a final class A surface around the part geometry with a second material. Then a fiber reinforced polyamide with an effective amount of an ABS material is compounded and the first injection mold cavity is used to form a part geometry. Thereafter, a colored polyurethane material is injected around the part geometry in the second injection molded cavity for providing a class A surface coating on the part.

Abstract: An apparatus and process for forming a predetermined three-dimensional (3D) object, in particular to an apparatus and method for making of a predetermined 3D object including an outer finished show surface without the use of post processing steps, and selectively printing three-dimension features onto another surface without compromising the integrity of the outer finished surface quality. A build platform of the apparatus includes a smooth surface to disperse deposited materials into a highly uniform base layer with exceptional surface quality on the interface between the deposited material and the build platform. The apparatus and process have the ability to produce an exceptionally smooth surface capable of achieving automotive standards for exterior components without the use of post-processing.

Abstract: A lap shear test fixture and method of use to test the performance of the weld interface in welded thermoplastic composite parts such as infrared welded or resistive implant welded or adhesive bonded composite parts. The specimens to be tested are provided from production-ready parts with typical geometry. The test fixture has at least two aligned blocks with at least two lateral support blocks that operably hold the specimen including two welded substrates. The test is performed in compression-mode at a predetermined crosshead speed until the maximum load produced by a universal testing machine makes the weld interface between the two thermoplastic substrates fail in shear mode.

Abstract: A primer containing graphene as an additive and a method of priming a filled polymer substrate for providing a Class A final paint surface. The method includes providing a substrate with reinforcement materials. A primer which includes from 0.5-5% by weight of graphene as an additive is applied to the substrate for coating the substrate. The primer is cured during heating of the resulting product for drying the substrate. The graphene acts to dissipate heat providing less differential of heat between the primer and the substrate and/or coatings applied on top of the primer which produces an improved final appearance of a paint over a fiber reinforced polymer material.

Abstract: A method for producing a Class “A” paintable surface on a fiber filled substrate part: the method provides a fiber filled polymer part having an outer show surface for use on a vehicle. This part is coated with a flexible primer coating substantially free of pigments for forming a primed surface capable of being painted for forming a Class “A” show surface for a vehicle.

Abstract: A lap shear test fixture and method of use to test the performance of the weld interface in welded thermoplastic composite parts such as infrared welded or resistive implant welded or adhesive bonded composite parts. The specimens to be tested are provided from production-ready parts with typical geometry. The test fixture has at least two aligned blocks with at least two lateral support blocks that operably hold the specimen including two welded substrates. The test is performed in compression-mode at a pre-determined crosshead speed until the maximum load produced by a universal testing machine makes the weld interface between the two thermoplastic substrates fail in shear mode.

Abstract: A method of reducing aldehyde emissions during injection molding of a part with a cellulosic fiber-reinforced polypropylene composition. An injection molding machine capable of the parameters necessary for injection molding of a cellulosic fiber-reinforced polypropylene composition is provided. Said injection molding machine including: a hopper for holding of a pelletized cellulosic fiber-reinforced polypropylene composition material; a feed throat portion; and, a mixing chamber installed in line with the injection molding machine between the hopper and the feed throat portion. Metering an effective amount of an aldehyde reducing composition into the mixing chamber containing pelletized cellulosic fiber-reinforced polypropylene composition and mixing the pelletized cellulosic fiber-reinforced polypropylene composition with the aldehyde reducing composition for wetting the surface of the pellets with the aldehyde reducing composition. A part is then injection molded with the wetted pelletized mixture.