Abstract: In an embodiment, heat sink system can comprise: an integrally formed plastic heat sink and a printed circuit board package, wherein the plastic heat sink comprises a thermally conductive plastic having a thermal conductivity of at least 1.0 W/mK. In another embodiment, hybrid heat sink system, comprising: an integrally formed plastic heat sink and an insert, wherein the plastic heat sink comprises a thermally conductive plastic, the plastic heat sink and the insert each having a cylindrical shape, and wherein the insert comprises a feature of lancing provisions, corrugations, embossing, holes, or a combination comprising at least one of the foregoing features.

Abstract: A structural body of a vehicle can comprises: a hollow metal component comprising walls that define a channel, wherein the metal component has a metal component length, and wherein the metal component is selected from the group consisting of beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and a plastic-metal hybrid reinforcement having a cavities therethrough, and a metal support having greater than or equal to 3 walls forming a support channel. The plastic element is located in the support channel wherein the reinforcement is located in the component channel.

Abstract: A structural body of a vehicle can comprises: a hollow metal component comprising walls that define a channel, wherein the metal component has a metal component length, and wherein the metal component is selected from the group consisting of beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and a plastic-metal hybrid reinforcement having a cavities therethrough, and a metal support having greater than or equal to 3 walls forming a support channel. The plastic element is located in the support channel wherein the reinforcement is located in the component channel.

Abstract: In one embodiment, a rail extension comprises: an energy absorber comprising a polymer body, and vehicle attachment tabs extending from one end of the energy absorber and configured to attach to a vehicle rail, and an attachment tab extending from another end of the energy absorber and configured to attach to a bumper beam. The energy absorber can comprise cells formed by cell walls extending a length of the energy absorber and forming cavities therethrough; and open channels formed on each side of the energy absorber, wherein the channels are defined by walls of adjacent cells. A vehicle can comprise: a bumper beam; a vehicle rail; and the rail extensions.

Abstract: In an embodiment, a heat dissipating system for a light can include: a light source comprising an LED; a reflector adjacent the LED; a housing around the LED module; and a flexible conductive connector attached at one end to a heat sink and at another end to the light source, and configured to conduct heat away from the light source and to the heat sink. The heat sink is located remote from the light source. In an embodiment, a method of dissipating heat away from a LED module can include: conducting heat from the LED module through a flexible conductive connector to a heat sink, wherein a lamp comprises the LED module, a housing, and a reflector, and wherein the heat sink is located external to the LED housing.

Abstract: In an embodiment, an impact device comprises: a metal component comprising greater than or equal to three walls forming a metal component channel; and a plastic component having a honeycomb structure with a plurality of walls defining comb channels therein. The combs channels are oriented perpendicular to at least one of the three walls, and the plastic component is inseparable from the metal component without damage to at least one of the metal component and the plastic component. A wall of the metal component can comprise an aperture, and wherein plastic material from the plastic component is located in the aperture.

Abstract: In an embodiment, an impact device comprises: a metal component comprising greater than or equal to three walls forming a metal component channel; and a plastic component having a honeycomb structure with a plurality of walls defining comb channels therein. The combs channels are oriented perpendicular to at least one of the three walls, and the plastic component is inseparable from the metal component without damage to at least one of the metal component and the plastic component. A wall of the metal component can comprise an aperture, and wherein plastic material from the plastic component is located in the aperture.

Abstract: In some embodiments, a headlamp assembly can comprise: a reflector, a mounting bracket, a housing, and a light source. The reflector can have a lip at a light source opening and a peripheral rim with a reflector portion extending from the lip to a peripheral rim. The mounting bracket can be configured to attach to the reflector. The mounting bracket can comprise attachment structures configured to mate with the lip, and adjustment features that enable horizontal, vertical, and pivotal adjustment. The light source can extend into the reflector through the light source opening.

Abstract: A steering wheel system can comprise: an armature comprising a rim comprising a plastic core, a covering between the plastic core and the protective outer layer, and a thermal management provision; a hub with a bush; and a spoke connecting the rim to the hub. A method for making a thermal management steering wheel can comprise: forming a plastic rim with a core having a channel with ribs, wherein during use, the ribs induce a change in direction and a change in velocity of a fluid flow through the channel; laser direct structuring electrically conductive material onto the core; disposing a foam material around the core; and disposing a protective material around the foam material.

Abstract: In an embodiment, an energy absorbing device comprises: a metal component comprising greater than or equal to three walls forming a metal component channel; and a plastic component having a honeycomb structure with a plurality of walls defining comb channels therein. The plastic component is located in the metal component channel forming a crash can. The plastic component is inseparable from the metal component without damage to the metal component and/or the plastic component. In one embodiment, a method of making an energy absorbing device can comprise: co-molding the metal component and the plastic component to form a crash can. The energy absorbing device can be used on a vehicle, adjacent to a vehicle component.

Abstract: In an embodiment, heat sink system can comprise: an integrally formed plastic heat sink and a printed circuit board package, wherein the plastic heat sink comprises a thermally conductive plastic having a thermal conductivity of at least 1.0 W/mK. In another embodiment, hybrid heat sink system, comprising: an integrally formed plastic heat sink and an insert, wherein the plastic heat sink comprises a thermally conductive plastic, the plastic heat sink and the insert each having a cylindrical shape, and wherein the insert comprises a feature of lancing provisions, corrugations, embossing, holes, or a combination comprising at least one of the foregoing features.

Abstract: In an embodiment, an energy absorbing device comprises: a metal component comprising greater than or equal to three walls forming a metal component channel; and a plastic component having a honeycomb structure with a plurality of walls defining comb channels therein. The plastic component is located in the metal component channel forming a crash can. The plastic component is inseparable from the metal component without damage to the metal component and/or the plastic component. In one embodiment, a method of making an energy absorbing device can comprise: co-molding the metal component and the plastic component to form a crash can. The energy absorbing device can be used on a vehicle, adjacent to a vehicle component.