Abstract: An apparatus for housing battery cells arranged in a cluster, the enclosure having a wall formed of a low-cost monolithic extrusion formed of a thermoplastic and defining a plurality of elongate parallel hollows extending across the enclosure. The extrusion can include a metal sheet fastened to one side to provide an out downward-facing barrier against heat and road debris.

Abstract: Abstract: An apparatus for providing structural support for a vehicle, the apparatus comprising a rocker panel component defining a channel extending along an axis, a partition disposed in the channel to define a first channel portion and a second channel portion, a first plastic reinforcement disposed in the first channel portion and coupled to the rocker panel component, the first plastic reinforcement defining a plurality of voids such that the first plastic reinforcement plastically deforms under a load at a first rate of deformation along the axis, a second plastic reinforcement disposed in the second channel portion and coupled to the rocker panel component, the second plastic reinforcement defining a plurality of voids such that the second plastic reinforcement plastically deforms under the load at a second rate of deformation along the axis, wherein the first rate of deformation is different than the second rate of deformation.

Abstract: The invention relates to a hybrid structure comprising a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base, and a thermoplastic second component moulded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component further comprising a locking portion that extends adjacently over at least part of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed, thus interlocking the first component in the thermoplastic second component. The invention relates as well to a method for manufacturing such a hybrid structure, and to a vehicle comprising such a hybrid structure.

Abstract: The invention relates to a hybrid structure comprising a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base, and a thermoplastic second component moulded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component further comprising a locking portion that extends adjacently over at least part of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed, thus interlocking the first component in the thermoplastic second component. The invention relates as well to a method for manufacturing such a hybrid structure, and to a vehicle comprising such a hybrid structure.

Abstract: A vehicle battery pack frame for a vehicle comprising: a base having a length and a width; side members on opposite sides of the base, extending along the length of the base, and attached to a periphery of the base; and crossbeams extending across the width of the base, between the side members; wherein each of the side members comprises a profiled body comprising a sidewall having a first surface facing the cross beams, and an opposite second surface; and a polymer reinforcement attached to the profiled body and facing the second surface of the sidewall of the profiled body.

Abstract: An energy absorbing device includes a honeycomb body having two or more tubes stacked transversely with one another along a longitudinal axis. The honeycomb body includes an inboard portion and an outboard portion. The inboard portion of the honeycomb body is arranged along the longitudinal axis and has an inboard portion bending stiffness. The outboard portion of the honeycomb body is arranged outboard of the longitudinal axis, is coupled to the inboard portion of the honeycomb body, and has an outboard portion bending stiffness. The outboard portion bending stiffness of the outboard portion is greater than the inboard portion bending stiffness of the inboard portion. Structural members for vehicle bodies and vehicle bodies are also described.

Abstract: A battery pack comprising: a battery comprising at least one battery cell, connectors and heat exchanger means, and a battery housing comprising: a bottom enclosure comprising at least a base and an upstanding peripheral wall, the bottom enclosure is suitable to contain the battery, a lid suitable for closing the bottom enclosure, and fixation means suitable to maintain the lid on the bottom enclosure in order to close the battery pack housing, characterized in that the lid comprises at least a protrusion, the protrusion is positioned in order to press the battery assembly towards the center of the module, wherein the battery is contained inside the bottom enclosure and the lid is covering the bottom enclosure and retained by the fixation means inside the battery housing, adjacent to the wall of the bottom enclosure and the battery.

Abstract: An energy absorbing device includes a composite or metallic component having greater than or equal to three walls forming a component channel with a longitudinal length and a polymeric component. The polymeric component has a honeycomb structure with two or more walls defining honeycomb tubes and supported within the component channel with the honeycomb tubes stacked transversely along the longitudinal length of the component channel. Ends of the honeycomb tubes abut the composite or metal component. The composite or metal component, or the polymeric component, has a bending stiffness greater than a bending stiffness of the honeycomb structure. Rocker assemblies and vehicle bodies are also described.

Abstract: A hybrid seating structure, comprising: a main structure formed from a thermoplastic material and injection molded as a single piece, comprising: a frame formed by a left channel, right channel, bottom channel, and top channel; wherein each channel is defined by an outside wall, an inside wall, and a connecting wall that extends between the outside wall and the inside wall, wherein the inside walls of each channel form an inner side of the frame, and the outside walls and connecting walls form an exterior side of the frame; and each channel comprises a first reinforcing rib structure disposed in the channel; wherein the outside wall of the left channel comprises a first reinforcement; and wherein the outside wall of the right channel comprises a second reinforcement.

Abstract: Hybrid energy absorbing assembly for attachment to a vehicle for a vehicle, comprising a bumper beam comprising a plastic material; and a towing assembly, wherein the towing assembly comprises a metal insert. The invention also relates to a metal insert for such a hybrid energy absorbing assembly. Moreover, the invention relates to a vehicle provided with such a hybrid towing bumper beam assembly, wherein the metal insert is connected to a body-in-white of the vehicle. Furthermore, the invention relates to a method for manufacturing such a hybrid towing bumper beam assembly for a vehicle, the method comprising placing the metal insert in a mold; introducing molten thermoplastic material, to a mold to in site form the energy absorbing assembly and thus overmolding the metal insert with the thermoplastic material, thereby embedding the metal insert in the bumper beam.

Abstract: An apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a body-in-white member having an inboard side and an outboard side, a reinforcing structure molded on the inboard side, and an energy absorbing structure molded on the outboard side. A method according to an exemplary aspect of the present disclosure includes, among other things, providing a body-in-white member having an inboard side and an outboard side, molding a reinforcing structure on the inboard side, and molding an energy absorbing structure on the outboard side.

Abstract: A hybrid structure includes a frame member with at least three walls, forming a channel having a convex portion where two walls meet. A concave deformation is present in at least one convex portion, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion. A plastic reinforcement member is present in the channel, wherein a portion of the reinforcement member extends into the opening and on the concave deformation.

Abstract: The invention relates to a hybrid structure comprising a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base, and a thermoplastic second component moulded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component further comprising a locking portion that extends adjacently over at least part of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed, thus interlocking the first component in the thermoplastic second component. The invention relates as well to a method for manufacturing such a hybrid structure, and to a vehicle comprising such a hybrid structure.

Abstract: An article of manufacture comprising a polyester composition, the article comprising, as measured by differential scanning calorimetry with a heating rate of 20 C per minute on first heating according to ASTM D3418, at least two different crystalline melting temperatures, wherein a first crystalline melting temperature and a second crystalline melting temperature are each independently 200-290 C; and a first heat of fusion and a second heat of fusion that are each independently at least 3 J/g, preferably wherein a ratio of the first heat of fusion to the second heat of fusion is 1:5-5:1, wherein the polyester composition comprises a first polyester having a phosphorous content of greater than or equal to 20 ppm, a second polyester, and 5-50 weight percent of a plurality of fibers, based on the total weight of the polyester composition, wherein the plurality of fibers have a diameter of 5-25 micrometers.

Abstract: An apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a body-in-white member having an inboard side and an outboard side, a reinforcing structure molded on the inboard side, and an energy absorbing structure molded on the outboard side. A method according to an exemplary aspect of the present disclosure includes, among other things, providing a body-in-white member having an inboard side and an outboard side, molding a reinforcing structure on the inboard side, and molding an energy absorbing structure on the outboard side.

Abstract: A lower member device (420) and a method of constructing a lower member device includes arranging a metallic/composite (602) component in preparation for molding a plastic portion such that the metallic/composite component will extend along a width of the plastic portion. The lower member device and method further including configuring the metallic/composite component to attach to a front end module of a vehicle with attachment portions 606, molding the plastic portion over the metallic/composite component, and forming strengthening portions arranged adjacent the metallic/composite component in the plastic portion during molding.

Abstract: A plastic energy absorption member (28) for an automobile bumper assembly (22) is disclosed. The plastic energy absorption member (28) includes a plastic crushable body (34) defining a first end and a second end opposite the first end along a length of the crushable body (34). The plastic energy absorption member (28) further includes a plastic first mounting portion (30) disposed proximate to the first end and monolithic with the plastic crushable body (34), the first mounting portion defining at least one first attachment member (38) configured to attach to the bumper (24), and a plastic second mounting portion (32) disposed proximate to the second end and monolithic with the plastic crushable body (34), the second mounting portion defining at least one second attachment member (42) configured to attach to the automobile rail (26). The energy absorption member (28) defines a plurality of voids (44) that each extend along at least a portion of the length of the crushable body (34).

Abstract: Hybrid energy absorbing assembly for attachment to a vehicle for a vehicle, comprising a bumper beam comprising a plastic material; and a towing assembly, wherein the towing assembly comprises a metal insert. The invention also relates to a metal insert for such a hybrid energy absorbing assembly. Moreover, the invention relates to a vehicle provided with such a hybrid towing bumper beam assembly, wherein the metal insert is connected to a body-in-white of the vehicle. Furthermore, the invention relates to a method for manufacturing such a hybrid towing bumper beam assembly for a vehicle, the method comprising placing the metal insert in a mold; introducing molten thermoplastic material, to a mold to in site form the energy absorbing assembly and thus overmolding the metal insert with the thermoplastic material, thereby embedding the metal insert in the bumper beam.

Abstract: A hybrid structure, comprising: a frame member comprising at least three walls forming a channel having a convex portion where two walls meet; a concave deformation in at least one of the convex portions, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion; and a plastic reinforcement member in the channel, wherein a portion of the reinforcement member extends into the opening and on the deformation.

Abstract: A lower member device (420) and a method of constructing a lower member device includes arranging a metallic/composite (602) component in preparation for molding a plastic portion such that the metallic/composite component will extend along a width of the plastic portion. The lower member device and method further including configuring the metallic/composite component to attach to a front end module of a vehicle with attachment portions 606, molding the plastic portion over the metallic/composite component, and forming strengthening portions arranged adjacent the metallic/composite component in the plastic portion during molding.