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: A structural battery pack includes a bottom cover, a bottom cell carrier, multiple battery cells, a cooling ribbon, a top cell carrier, and a top cover. The bottom cover has a rectangular shape that defines a longitudinal direction and a lateral direction. The bottom cell carrier is coupled to the bottom cover, and defines multiple bottom holders. The bottom holders are arranged in a hexagon pattern that defines multiple rows in the longitudinal direction and multiple columns in the lateral direction. The top cell carrier is coupled to the top cover, defines multiple top holders, and includes an interconnect board that interconnects the battery cells. The top holders are arranged in the hexagon pattern. The battery cells are installed in the bottom cell carrier and the top cell carrier. Each battery cell has a cylindrical shape. The cooling ribbon is installed between the battery cells along the rows.

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 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 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 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.

Abstract: In accordance with an exemplary embodiment, a vehicle is provided that includes: a body; a drive system configured to propel the body; and a suspension system coupled to the drive system, the suspension system including a shock cap assembly including: a strut component; a cap component attached to the strut component; and an attachment mechanism configured for attachment to a body of the vehicle, such that the shock cap assembly is configured to be accessed from a front wheel well of the vehicle.

Abstract: A body structure for an automotive vehicle includes an enclosure for a power source, an upper shear structure assembly and a lower shear structure assembly. The enclosure includes a front cross-member, a rear cross-member, a left rocker and a right rocker. The upper and lower shear structure assemblies are disposed across the top and bottom of the enclosure, respectively, and are fastened to respective top and bottom surfaces of the cross-members and rockers. The upper and lower shear structure assemblies may include respective front and rear generally trapezoidal sections configured for attachment to respective front and rear box structures. Each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.

Abstract: In accordance with an exemplary embodiment, a vehicle is provided that includes: a body; a drive system configured to propel the body; and a suspension system coupled to the drive system, the suspension system including a shock cap assembly including: a strut component; a cap component attached to the strut component; and an attachment mechanism configured for attachment to a body of the vehicle, such that the shock cap assembly is configured to be accessed from a front wheel well of the vehicle.

Abstract: A body structure for an automotive vehicle includes an enclosure for a power source, an upper shear structure assembly and a lower shear structure assembly. The enclosure includes a front cross-member, a rear cross-member, a left rocker and a right rocker. The upper and lower shear structure assemblies are disposed across the top and bottom of the enclosure, respectively, and are fastened to respective top and bottom surfaces of the cross-members and rockers. The upper and lower shear structure assemblies may include respective front and rear generally trapezoidal sections configured for attachment to respective front and rear box structures. Each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.

Abstract: A vehicle includes a frame assembly, a body, and a first strip isolator disposed between the body and the frame.

Abstract: An electric vehicle includes a chassis frame, a battery pack, and a brace. The battery pack includes a support structure vertically spaced at least in-part from the chassis frame. The first brace extends between, and is engaged to, the chassis frame and the support structure.

Abstract: Disclosed are active vehicle seat assemblies, methods for making and using such seat assemblies, and vehicles with active seat assemblies for counteracting unwanted inertial forces. An active vehicle seat assembly is disclosed that includes an occupant chair with interconnected seat and backrest portions. A motion sensor detects motion of the occupant chair and outputs signals indicative thereof. An automated platform movably mounts the occupant chair to the vehicle body. The platform includes: a pitch plate that pivots about two lateral axes; a pitch actuator that selectively pivots the pitch plate; a roll plate that pivots about two longitudinal axes; and a roll actuator that selectively pivots the roll plate. An on-board controller responds to signals from the motion sensor indicative of inertial motion disturbances to the chair by transmitting control signals to the pitch and/or roll actuators to pivot the pitch and/or roll plates to thereby counteract the inertial disturbances.

Abstract: An electric vehicle includes a chassis frame, a battery pack, and a brace. The battery pack includes a support structure vertically spaced at least in-part from the chassis frame. The first brace extends between, and is engaged to, the chassis frame and the support structure.

Abstract: Disclosed are active vehicle seat assemblies, methods for making and using such seat assemblies, and vehicles with active seat assemblies for counteracting unwanted inertial forces. An active vehicle seat assembly is disclosed that includes an occupant chair with interconnected seat and backrest portions. A motion sensor detects motion of the occupant chair and outputs signals indicative thereof. An automated platform movably mounts the occupant chair to the vehicle body. The platform includes: a pitch plate that pivots about two lateral axes; a pitch actuator that selectively pivots the pitch plate; a roll plate that pivots about two longitudinal axes; and a roll actuator that selectively pivots the roll plate. An on-board controller responds to signals from the motion sensor indicative of inertial motion disturbances to the chair by transmitting control signals to the pitch and/or roll actuators to pivot the pitch and/or roll plates to thereby counteract the inertial disturbances.

Abstract: Disclosed are wheel assemblies for motor vehicle powertrains, methods for making and methods for using wheel assemblies, and motor vehicles with wheel units each composed of a tire and a wheel assembly. For example, a multi-hub wheel assembly for a motor vehicle is disclosed. The motor vehicle includes a tire and a suspension component, such as a hub-and-bearing assembly, mounted to the vehicle body. The wheel assembly includes an outer wheel with an annular rim well attached to a central hub. The central hub mounts onto the vehicle's suspension component, e.g., via lugs and bolts, while the tire mounts onto the rim well. The wheel assembly also includes an intermediate hub with a deflection annular rim attached to a mounting base. The mounting base is attached to the outer wheel. The intermediate hub mounts inside a hollow core of the outer wheel, interposed between the central hub and the suspension component.

Abstract: A vehicle includes a frame assembly, a body, and a first strip isolator disposed between the body and the frame.

Abstract: Disclosed are shear plates for structurally connecting vehicle chassis front cradles to battery pack support trays, methods for making and methods for using such shear plates, and electric vehicles with a chassis frame having a front cradle coupled to a battery pack support tray by a shear plate. A shear plate is disclosed for connecting a front cradle to a traction battery pack. The shear plate includes an elongated plate body with opposing fore and aft braces connected by opposing starboard and port braces. The fore brace directly mechanically couples to a cross member of the front cradle, whereas the aft brace directly mechanically couples to a support tray of the traction battery pack. The shear plate's elongated body is designed to transmit in-plane and torsional forces received from the front cradle via the fore brace, through the starboard and port braces, to the support tray via the aft brace.