Abstract: A hazard beacon has an interface to a vehicle wiring harness configured to detect that vehicle emergency indicators have been deployed, a plurality of separately strobe capable light segments forming a hazard symbol, and a microcontroller controlling operation of the plurality of separately strobe capable light segments.

Abstract: An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

Abstract: A friction stir welded assembly includes a first workpiece having an interior portion with opposed interior walls, a second workpiece having an interior portion with opposed interior walls, and an insert positioned within the interior portion of the first workpiece and the interior portion of the second workpiece. The insert extends between and abuts at least one of the opposed interior walls of the first workpiece and the opposed interior walls of the second workpiece and a friction stir weld is between the first workpiece to the second workpiece. A joining end of the first workpiece and a joining end of the second workpiece form a butt joint or a lap joint between the first and second workpieces, and the friction stir weld is a butt weld or a lap weld, respectively, between the first and second workpieces.

Abstract: An inner mandrel for forming a variable taper component includes a plurality of interlocking pieces and a brace. Each interlocking piece defines opposed tapered edge faces, a first surface, and a tapered second surface opposite the first surface. One of the edge faces defines a locking feature and another of the edge faces defines a receiving feature engaging the locking feature of an adjacent interlocking piece. The first surface defines a variable taper and a plurality of recesses. The brace secures the plurality of interlocking pieces to each other in a concentric arrangement about a central axis. A maximum width of each of the interlocking pieces is smaller than a minimum width of an end portion of the variable taper component. A central portion of the variable taper component is wider than the end portions.

Abstract: An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

Abstract: Tooling for use in forming a variable taper component is provided. The tooling includes an inner mandrel and an outer mandrel disposed around the inner mandrel. The inner mandrel includes a master insert defining opposed tapered edge faces, an external surface having a variable taper and a plurality of recesses configured to receive at least a portion of the variable taper component, and a tapered internal surface. The inner mandrel also includes a plurality of interlocking pieces arranged concentrically around the master insert, and a tapered inner sleeve disposed against the tapered internal surfaces of the plurality of interlocking pieces and the master insert. The outer mandrel defines a corresponding plurality of recesses configured to receive at least a portion of the variable taper component, wherein a maximum width of the interlocking pieces and the master insert is smaller than a minimum width of ends of the variable taper component.

Abstract: A friction stir welded assembly includes a first workpiece having an interior portion with opposed interior walls, a second workpiece having an interior portion with opposed interior walls, and an insert positioned within the interior portion of the first workpiece and the interior portion of the second workpiece. The insert extends between and abuts at least one of the opposed interior walls of the first workpiece and the opposed interior walls of the second workpiece and a friction stir weld is between the first workpiece to the second workpiece. A joining end of the first workpiece and a joining end of the second workpiece form a butt joint or a lap joint between the first and second workpieces, and the friction stir weld is a butt weld or a lap weld, respectively, between the first and second workpieces.

Abstract: Tooling for use in forming a variable taper component is provided. The tooling includes an inner mandrel and an outer mandrel disposed around the inner mandrel. The inner mandrel includes a master insert defining opposed tapered edge faces, an external surface having a variable taper and a plurality of recesses configured to receive at least a portion of the variable taper component, and a tapered internal surface. The inner mandrel also includes a plurality of interlocking pieces arranged concentrically around the master insert, and a tapered inner sleeve disposed against the tapered internal surfaces of the plurality of interlocking pieces and the master insert. The outer mandrel defines a corresponding plurality of recesses configured to receive at least a portion of the variable taper component, wherein a maximum width of the interlocking pieces and the master insert is smaller than a minimum width of ends of the variable taper component.

Abstract: A side rail for a motor vehicle sub-frame includes (a) a first component having a first extrusion axis and (b) a second component having a second extrusion axis wherein the first and second components are joined with the first extrusion axis and the second extrusion axis forming an included angle of between 60 and 90 degrees.

Abstract: A cross member for a motor vehicle sub-frame includes (a) a hollow body having an extrusion axis and (b) a wall having a first edge and a second edge. The wall is positioned inside and extends across the hollow body with the first edge and the second edge joined to the hollow body.

Abstract: A sub-frame assembly supports a pair of wheels on a vehicle. The base may be an extrusion having a matrix of panels extending in a vertical direction. The sub-frame assembly has control arm brackets disposed on opposing ends of the base and attachment towers extending above the brackets providing attachment points to connect portions of an independent suspension to the vehicle and support a pair of wheels. The base, control brackets and attachment towers may be individual modular pieces. Left and right hand control brackets and attachment towers may be provided by respective unitary support pieces attached to opposing ends of the base. The unitary support pieces may be extrusions having panels extending in a transverse direction, nonaxial to the base. The base, control arm brackets and attachment towers, alternatively, may be provided by a single unitary extrusion having a matrix of panels extending in a transverse direction.

Abstract: A vehicle having a body including a roof supported between spaced roof rails. A plurality of roof bows extend between and are attached to the roof rails that reinforce the roof. The roof bows define an air distribution duct that includes an air inlet and at least one air vent. The air distribution duct defines a downwardly facing open channel that is closed by a headliner.

Abstract: A motor vehicle sub-frame is provided. That motor vehicle sub-frame includes a front cross member, a rear cross member and first and second side rails connected to the front and rear cross members at each side of the sub-frame. The side rails both include a first component having a first extrusion axis and a second component having a second extrusion axis. The first and second components are joined together so that the two components effectively form an at least partially closed or boxed construction providing enhanced bending and torsion resistances while minimizing component weight.

Abstract: A vehicle having a body including a roof supported between spaced roof rails. A plurality of roof bows extend between and are attached to the roof rails that reinforce the roof. The roof bows define an air distribution duct that includes an air inlet and at least one air vent. The air distribution duct defines a downwardly facing open channel that is closed by a headliner.

Abstract: An acoustic panel for a vehicle includes a floor panel, an underbody acoustic shield, and a perimeter seal positioned between the floor panel and the underbody acoustic shield to form a pocket of trapped air. The pocket of trapped air can further reduce a transmission of noise through the floor panel into the vehicle interior.

Abstract: An exemplary vehicle flow influencing assembly includes a deflector formed together with a seal that provides a portion of a glass run for a side window of a vehicle. The deflector projects outward from the vehicle when the side window is lowered such that the deflector influences flow over an opening to a passenger compartment of the vehicle. A vehicle flow influencing assembly includes a pillar that is directly forward a side window of a vehicle, and a deflector configured to influence flow over an opening to a passenger compartment of the vehicle. The opening is provided by positioning the side window in an open position. The deflector extends longitudinally in a direction aligned with the pillar. The deflector projects outward from a primary surface of the pillar when the side window is closed and when the side window is open.

Abstract: An impact absorbing assembly comprises a CFRP part including a first portion and a second portion that are connected by a metal bending hinge connector. The metal bending hinge connector bends in response to an impact force being applied to the assembly to inhibit the CFRP part from cracking. The metal bending hinge connector may be a tubular member that defines an opening extending from a first end to a second end of the tubular member. The tubular member receives the first CFRP part in the first end and the second CFRP part in the second end. The impact absorbing assembly may be, for example, a longitudinally extending rail or a sub-frame arm.

Abstract: A subframe for a vehicle includes a subframe structure and a rear end joint. The rear end joint is formed on the subframe structure for attachment to a floor via a bolt. The rear end joint defines a notch, having a collar surrounding the bolt. The rear end joint is configured such that, upon impact, the rear end joint interacts with the bolt to break the collar, split the notch, and detach the subframe structure from the floor.

Abstract: A vehicle tailgate includes a frame, pair of hinges, inner tailgate panel, and outer tailgate panel. The frame has a first outer side-member and a second outer side-member. Each of the outer side-members is secured to ends of a lower outer cross-member. The outer side-members each have an internal surface and an external surface. The internal surfaces define T-slots. One of the pair of hinges is secured to each external surface of the outer side-members. The inner and outer tailgate panels are secured to opposing outer sides of the frame such that the external surfaces of the outer side-members remain exposed.

Abstract: A motor vehicle sub-frame is provided. That motor vehicle sub-frame includes a front cross member, a rear cross member and first and second side rails connected to the front and rear cross members at each side of the sub-frame. The side rails both include a first component having a first extrusion axis and a second component having a second extrusion axis. The first and second components are joined together so that the two components effectively form an at least partially closed or boxed construction providing enhanced bending and torsion resistances while minimizing component weight.