Abstract: In a method of making a carbon fiber, PAN (poly(acrylonitrile-co methacrylic acid)) is dissolved into a solvent to form a PAN solution. The PAN solution is extruded through a spinneret, thereby generating at least one precursor fiber. The precursor fiber is passed through a cold gelation medium, thereby causing the precursor fiber to gel. The precursor fiber is drawn to a predetermined draw ratio. The precursor fiber is continuously stabilized to form a stabilized fiber. The stabilized fiber is continuously carbonized thereby generating the carbon fiber. The carbon fiber is wound onto a spool. A carbon fiber has a fiber tensile strength in a range of 5.5 GPa to 5.83 GPa. The carbon fiber has a fiber tensile modulus in a range of 350 GPa to 375 GPa. The carbon fiber also has an effective diameter in a range of 5.1 ?m to 5.2 ?m.

Abstract: The present disclosure provides a roof for a vehicle upper body structure. The roof includes a body extending between a first side and a second side, and extending between a front end and a back end. The front end is configured to be coupled to a header. The body includes a polymer and a plurality of fibers. At least a portion of the body has a transparency of greater than or equal to about 4%.

Abstract: Presented are multilayer composite panels for motor vehicles, methods for making/using such panels, and motor vehicles with transparent composite roof panels having localized reinforcement features. A sandwich-type multilayer composite panel contains one or more exterior layers each including a transparent rigid material, one or more bonding layers each including a transparent adhesive material, and one or more structural reinforcement layers each including a fiber-reinforced polymer material. Each structural reinforcement layer may be attached directly to a bonding layer and/or exterior layer. The composite panel may also include one or more IR-reflective layers, one or more light-absorbing sunshade layers, and one or more insulating low-k layers.

Abstract: In a method of making a carbon fiber, PAN (poly(acrylonitrile-co methacrylic acid)) is dissolved into a solvent to form a PAN solution. The PAN solution is extruded through a spinneret, thereby generating at least one precursor fiber. The precursor fiber is passed through a cold gelation medium, thereby causing the precursor fiber to gel. The precursor fiber is drawn to a predetermined draw ratio. The precursor fiber is continuously stabilized to form a stabilized fiber. The stabilized fiber is continuously carbonized thereby generating the carbon fiber. The carbon fiber is wound onto a spool. A carbon fiber has a fiber tensile strength in a range of 5.5 GPa to 5.83 GPa. The carbon fiber has a fiber tensile modulus in a range of 350 GPa to 375 GPa. The carbon fiber also has an effective diameter in a range of 5.1 ?m to 5.2 ?m.

Abstract: In a method of making a carbon fiber, PAN (poly(acrylonitrile-co methacrylic acid)) is dissolved into a solvent to form a PAN solution. The PAN solution is extruded through a spinneret, thereby generating at least one precursor fiber. The precursor fiber is passed through a cold gelation medium, thereby causing the precursor fiber to gel. The precursor fiber is drawn to a predetermined draw ratio. The precursor fiber is continuously stabilized to form a stabilized fiber. The stabilized fiber is continuously carbonized thereby generating the carbon fiber. The carbon fiber is wound onto a spool. A carbon fiber has a fiber tensile strength in a range of 5.5 GPa to 5.83 GPa. The carbon fiber has a fiber tensile modulus in a range of 350 GPa to 375 GPa. The carbon fiber also has an effective diameter in a range of 5.1 ?m to 5.2 ?m.

Abstract: The present disclosure provides a header for a vehicle upper body structure. The header includes an elongated body extending between a first side and a second side. The elongated body includes a polymer and a plurality of fibers. The elongated body includes a front end and a back end. The front end is configured to be coupled to a windshield. The back end is configured to be coupled to a roof. At least a portion of the elongated body has a transparency of greater than or equal to about 4%.

Abstract: The present disclosure provides a header for a vehicle upper body structure. The header includes an elongated body extending between a first side and a second side. The elongated body includes a polymer and a plurality of fibers. The elongated body includes a front end and a back end. The front end is configured to be coupled to a windshield. The back end is configured to be coupled to a roof. At least a portion of the elongated body has a transparency of greater than or equal to about 4%.

Abstract: The present disclosure provides a roof for a vehicle upper body structure. The roof includes a body extending between a first side and a second side, and extending between a front end and a back end. The front end is configured to be coupled to a header. The body includes a polymer and a plurality of fibers. At least a portion of the body has a transparency of greater than or equal to about 4%.

Abstract: Presented are multilayer composite panels for motor vehicles, methods for making/using such panels, and motor vehicles with transparent composite roof panels having localized reinforcement features. A sandwich-type multilayer composite panel contains one or more exterior layers each including a transparent rigid material, one or more bonding layers each including a transparent adhesive material, and one or more structural reinforcement layers each including a fiber-reinforced polymer material. Each structural reinforcement layer may be attached directly to a bonding layer and/or exterior layer. The composite panel may also include one or more IR-reflective layers, one or more light-absorbing sunshade layers, and one or more insulating low-k layers. The fibers of each structural reinforcement layer are localized to a discrete region within the composite panel's plan-view profile.

Abstract: Methods of making a composite article are provided herein. The method can include an unwinding step including unwinding a fiber substrate material from a creel at an unwinding velocity and an impregnation step including applying an uncured resin composition to the fiber substrate material to form a resin-fiber material. The method further includes a winding step comprising applying the resin-fiber material onto a shaped surface at a winding velocity and a solidifying step comprising applying heat to the resin-fiber material to initiate an exothermic reaction comprising polymerization, cross-linking, or both of the uncured resin composition. Temperature of the resin-fiber material can be monitored during operation of the method and a polymerization front velocity set point (vpfs) and an operating polymerization front velocity (vpfo) can be determined. Parameters can be adjusted to maintain a vpfo that is substantially the same as the vpfs. Systems for performing said methods are also provided.

Abstract: A method of manufacturing a unitary energy absorbing structure for a vehicle includes providing a first mold having a cavity receiving a first mandrel and a second mold having a cavity receiving a second mandrel. At least one mandrel segment is positioned in the first mold cavity and cooperates with the first mandrel. One or more layers of composite material at least partially cover the first mold cavity, first mandrel, at least one mandrel segment and second mold. The unitary structure is formed from the first layer, the second layer and the third layer of composite material with the first mandrel, the at least one mandrel segment and the second mandrel in the first mold and the second mold.

Abstract: A rocker assembly for a vehicle body structure includes a rocker rail having a boxed cross-section defining a rocker rail interior space, a rocker rail length, and a rocker rail outer surface along the length. The rocker rail defines at least one aperture connecting the interior space and the panel outer surface. The rocker assembly also includes an insert member configured to fit within the rocker rail interior space and extend along the panel length to reinforce the panel. The insert member includes at least one projection configured to match up with and extend at least partially through a respective at least one aperture. The projection(s) are configured to reinforce the rocker rail by opposing deformation of the boxed cross-section. The projection(s) oppose deformation via interference with the boxed cross-section at the respective aperture(s) when the rocker rail is subjected to an applied load perpendicular to the panel outer surface.

Abstract: Presented are fiber-reinforced polymer (FRP) composite components for vehicle body structures, methods for making/using such components, and motor vehicles equipped with such components. A vehicle body structure includes one or more elongated support rails (e.g., a pair of lateral roof rails) each with an inner contoured rail panel joined to an outer contoured rail panel to define an internal rail cavity. One or more elongated support pillars (e.g., front, side, and/or back vehicle pillars) adjoin the support rail(s) and each includes an inner contoured pillar panel joined to an outer contoured pillar panel to define an internal pillar cavity coupled to the internal rail cavity. One or both contoured pillar panels and one or both contoured rail panels is/are formed, in whole or in part, from an FRP material. A structural reinforcement insert may be located inside the adjoined pillar and rail, filling a discrete region within the internal cavities.

Abstract: A rocker assembly for a vehicle body structure includes a rocker rail having a boxed cross-section defining a rocker rail interior space, a rocker rail length, and a rocker rail outer surface along the length. The rocker rail defines at least one aperture connecting the interior space and the panel outer surface. The rocker assembly also includes an insert member configured to fit within the rocker rail interior space and extend along the panel length to reinforce the panel. The insert member includes at least one projection configured to match up with and extend at least partially through a respective at least one aperture. The projection(s) are configured to reinforce the rocker rail by opposing deformation of the boxed cross-section. The projection(s) oppose deformation via interference with the boxed cross-section at the respective aperture(s) when the rocker rail is subjected to an applied load perpendicular to the panel outer surface.

Abstract: Presented are fiber-reinforced polymer (FRP) composite components for vehicle body structures, methods for making/using such components, and motor vehicles equipped with such components. A vehicle body structure includes one or more elongated support rails (e.g., a pair of lateral roof rails) each with an inner contoured rail panel joined to an outer contoured rail panel to define an internal rail cavity. One or more elongated support pillars (e.g., front, side, and/or back vehicle pillars) adjoin the support rail(s) and each includes an inner contoured pillar panel joined to an outer contoured pillar panel to define an internal pillar cavity coupled to the internal rail cavity. One or both contoured pillar panels and one or both contoured rail panels is/are formed, in whole or in part, from an FRP material. A structural reinforcement insert may be located inside the adjoined pillar and rail, filling a discrete region within the internal cavities.

Abstract: Presented are fiber-reinforced polymer (FRP) composite components for motor vehicles, methods for making and using such components, and motor vehicles with unitary FRP-composite vehicle roof rail-and-panel structures. A vehicle body structure for a motor vehicle includes one or more elongated support rails, each of which includes at least two contoured rail panels that are joined together to define therebetween an internal rail cavity. At least one of these contoured rail panels is formed with an FRP material. The vehicle body structure also includes a body panel that is formed with the same FRP material. The body panel includes a main panel section with one or more stepped interfaces that each projects transversely from a respective side of the main panel section and mounts thereon one of the contoured rail panels. The body panel and a contoured rail panel of each support rail are integrally formed as a single-piece, unitary structure.

Abstract: The present disclosure relates to multi-compound fiber reinforced composites and methods of making the same using frontal polymerization and targeted photosensitizer additives. In various aspects, the method may include disposing one or more layers in a mold cavity, where each of the one or more layers includes a fiber material and a first compound. The method may further includes disposing a second compound in the mold cavity, where the second compound includes a photosensitizer material. Further still, the method may include initiating photopolymerization of the photosensitizer using an ultraviolet light source, removing ultraviolet light source, and/or completing polymerization of the one or more layers so as to form the fiber-reinforced composite.

Abstract: Presented are multilayer composite panels for motor vehicles, methods for making/using such panels, and motor vehicles with transparent composite roof panels having localized reinforcement features. A sandwich-type multilayer composite panel contains one or more exterior layers each including a transparent rigid material, one or more bonding layers each including a transparent adhesive material, and one or more structural reinforcement layers each including a fiber-reinforced polymer material. Each structural reinforcement layer may be attached directly to a bonding layer and/or exterior layer. The composite panel may also include one or more IR-reflective layers, one or more light-absorbing sunshade layers, and one or more insulating low-k layers. The fibers of each structural reinforcement layer are localized to a discrete region within the composite panel's plan-view profile.

Abstract: Presented are multilayer composite panels for motor vehicles, methods for making/using such panels, and motor vehicles with transparent composite roof panels having localized reinforcement features. A sandwich-type multilayer composite panel contains one or more exterior layers each including a transparent rigid material, one or more bonding layers each including a transparent adhesive material, and one or more structural reinforcement layers each including a fiber-reinforced polymer material. Each structural reinforcement layer may be attached directly to a bonding layer and/or exterior layer. The composite panel may also include one or more IR-reflective layers, one or more light-absorbing sunshade layers, and one or more insulating low-k layers.

Abstract: Presented are structurally reinforced components for vehicle body structures, methods for making/using such components, and motor vehicles equipped with such components. A vehicle body structure includes an elongated support rail (e.g., a pair of lateral roof rails) with an inner contoured rail panel joined to an outer contoured rail panel to define an internal rail cavity. An elongated support pillar (e.g., front, side, and/or back vehicle pillars) adjoins the support rail and includes an inner contoured pillar panel joined to an outer contoured pillar panel to define an internal pillar cavity coupled to the internal rail cavity. The inner rail and pillar panels may be integrally from as a single-piece structure, and the outer rail and pillar panels may be integrally from as a single-piece structure. A structural reinforcement insert is located inside the support pillar and support rail, filling a discrete region within the rail cavity and pillar cavity.