Abstract: A method of near net shaping a rare earth permanent magnet and a permanent magnet. The method includes introducing a magnetic material powder into a die, closing the die and shock compacting the powder in the die and sintering the compacted magnet powder to form the rare earth permanent magnet part. In one form, the magnetic material being subjected to compaction is a mixture made up of two or more different magnetic material powder precursors. Additional materials may be added to the mixture. One such additional material may be a lubricant to reduce the likelihood of cracking, while another may be a coating to provide oxidation protection of the mixture. Evacuation or inert environments may also be used either prior to or in conjunction with the sintering or related high-temperature part of the process.

Abstract: A vehicle structure includes a frame having a first frame rail and a second frame rail. The first and second frame rails are spaced apart by a distance and are substantially parallel to one another. The vehicle structure also includes a vehicle body attached to the frame. The vehicle structure also includes a cradle mounted under the vehicle body to each of the first and second frame rails and configured to support a vehicle drivetrain subassembly. The vehicle structure additionally includes a panel attached to each of the first and second frame rails and the cradle, and configured to stiffen the vehicle structure.

Abstract: An energy absorber system for a vehicle includes a brace assembly having a front end. The system includes an energy absorber attachable to the assembly and having an inner wedge and an outer wedge. The inner wedge is attachable to the front end, defines a cavity, and has a primary side, a secondary side, a proximal side, and a distal side. The outer wedge is attachable to the inner wedge to cover the cavity, and has a first side configured for contacting and covering the primary side, a second side configured for contacting and covering the secondary side, a third side configured for contacting and covering the proximal side, a fourth side extending from the third side at an angle of less than or equal to 90 degrees and having a deflection surface and an interior surface, and a plurality of bulkheads projecting from the inner surface.

Abstract: A trim assembly, such as a center console for a vehicle, includes a base portion, a cover portion and a holding unit. The cover portion defines a cover opening, and is attached to the base portion. The holding unit is disposed between the cover portion and the base portion, and is rotatably supported by the base portion for rotation about a rotation axis between a bin storage position and a cup-holder storage position. A bin storage position presents a bin aperture defined by a first side of the holding unit adjacent the cover opening to provide access to an open interior region of the holding unit through the cover opening for storage. A cup-holder storage position presents a cup aperture defined by a second side of the holding unit adjacent the cover opening to secure a cup within the interior region of the holding unit.

Abstract: An exhaust manifold for at least a portion of an internal combustion engine having a defined number of combustion chambers includes a plurality of inlet ports and four outlet ports. A first pair of the four outlet ports are disposed in gas flow communication with a first subset of the plurality of inlet ports, and a second pair of the four outlet ports different from the first pair are disposed in gas flow communication with a second subset of the plurality of inlet ports different from the first subset.

Abstract: An adaptable bin includes a bin floor, at least two bin side walls, and one or more bin end walls. The bin floor, bin side walls, and bin end wall define a primary storage volume and define a bin opening allowing access to the primary storage volume. The adaptable bin also includes a secondary shelf moveable between a collapsed position and an expanded position. The secondary shelf defines a secondary storage volume in the expanded position. The secondary shelf includes a first shelf segment and a first hinge, which rotatably connects the first shelf segment to the bin end wall, and a second shelf segment and a second hinge, which rotatably connects the first and second shelf segments. The first and second shelf segments are substantially parallel to the bin end wall in the collapsed position and are substantially perpendicular to the bin end wall in the expanded position.

Abstract: A seat assembly for a motor vehicle is provided. The seat assembly includes a seat back portion and a removable and stowable head restraint. The seat back portion has a first surface and is configured to occupy one of an upright seating position and a folded cargo position. The head restraint is configured to be coupled to the first surface of the seat back portion. The head restraint is configured to occupy one of a deployed position and a stowed position. The head restraint remains secured to the seat back portion in each of the deployed position and the stowed position. Specifically, the head restraint occupies the stowed position when the seat back portion occupies the folded cargo position.

Abstract: A system and method for reducing the relative movement between adjacent fuel cells within a fuel cell stack includes an improved strategy for distributing an acceleration load over a fuel cell stack while maintaining stack performance after exposure to high acceleration loads. The system comprises a fuel cell stack comprising a plurality of fuel cells enclosed by a housing. A curable material occupies at least a portion of a lateral space located between the edges of each fuel cell in the stack and an interior wall of the housing. Upon occurrence of high acceleration loads within the housing, the curable material transmits the acceleration load from the housing to more evenly distribute the load to the edges of the fuel cells. A plurality of dams may be secured between the housing and the fuel cell stack forming channels for receiving the curable material.

Abstract: Disclosed are methods for fabricating a cathode composite structure to improve fuel cell performance. The methods comprise preparing a cathode composition for a cathode layer, the cathode composition having an average particle size distribution of from about 0.1 to about 30 microns, and simultaneously depositing the cathode composition and at least one other composition onto a substrate such that a cathode layer is formed on the substrate and at least one other layer is formed on the cathode layer to form a cathode composite structure.

Abstract: A number of variations of the invention may include a method including providing a front lower control arm attachment system including a sleeve locator stamping and at least one threaded sleeve extending there through, and attaching the front lower control arm attachment system to a vehicle engine cradle. A number of variations of the invention may include a front lower control arm attachment system including a sleeve locator stamping and at least one threaded sleeve extending through the sleeve locator stamping and secured thereto.

Abstract: An engine assembly includes a two-cylinder engine, an intake assembly, and an air-oil separator. The two-cylinder engine defines a first cylinder bore, a first combustion chamber, a second cylinder bore, a second combustion chamber, and a crankcase volume. The engine further includes a first piston disposed within the first cylinder bore, and a second piston disposed within the second cylinder bore. The intake assembly includes an intake manifold in fluid communication with each of the first and second combustion chambers, and the air-oil separator defines a separator volume and in fluid communication with each of the crankcase volume and the intake manifold. A reciprocal, synchronous motion of the first and second pistons is operative to exhale gas from the crankcase volume through the separator volume and into the intake manifold.

Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: Methods and apparatus are provided for attenuating vibrations in the header of a convertible vehicle. The apparatus includes a fluid damper configured to be coupled to a header of a convertible vehicle and an accelerometer for sensing vibrations in the header and providing a signal to adjust the fluid damper thereby attenuating the vibrations. A method is provided which includes receiving a signal indicating a vibration in a header of a convertible vehicle and adjusting a fluid damper coupled to the header in response to the signal thereby attenuating the vibration.

Abstract: Vehicle range projection includes detecting, via a vehicle antenna, a key fob within range of the vehicle. The key fob is associated with an individual. The vehicle range projection also includes searching, via a computer processor embedded in the vehicle, a database for a record having an identifier that matches an identifier of the key fob. The record stores historical drive cycle data associated with the key fob and the individual. The vehicle range projection further includes retrieving the historical drive cycle data and calculating a projected electric range value indicative of a distance in which the vehicle is capable of traveling on electric-only power. The projected electric range value is calculated as a function of a distance calculated based on available battery charge that is adjusted based on a driving style of the individual. The driving style of the individual is determined from the historical drive cycle data.

Abstract: Methods and apparatus are provided for controlling a boost converter. In one embodiment, the method processes a command signal in a slew rate limiting circuit. The output of the slew rate limiting circuit is then processed using one or more feedback parameters from the proportional integrator to provide a processed command signal. The processed command signal is processed with a controlled signal to provide an error signal which is provided to the proportional integrator to provide a current command signal. In one embodiment, the apparatus includes an error generating circuit configured to provide a processed command signal using one or more feedback parameters from the proportional integrator, and to provide the error signal by subtracting a signal to be controlled from the processed command signal. A slew rate limiting circuit is used to receive a command signal and provide an output to the error generating circuit.

Abstract: Disclosed are methods for fabricating a reinforced membrane electrode assembly having one or more freestanding external reinforcement layers. The method comprises providing a freestanding external reinforcement layer, and depositing a catalyst solution and membrane solution onto at least a portion of the freestanding external reinforcement layer.

Abstract: A transmission for a vehicle and a method of assembling a modular motor assembly in the transmission are disclosed. The transmission includes a housing defining a cavity along a longitudinal axis. The transmission further includes a first motor/generator and a second motor/generator each disposed in the cavity. The transmission also includes a first support supporting the first motor/generator such that the first motor/generator is mounted to the first support to define a first modular unit. The first modular unit is attached to the housing within the cavity. The transmission further includes a second support supporting the second motor/generator such that the second motor/generator is mounted to the second support to define a second modular unit. The second modular unit is attached to the first modular unit such that the first and second modular units align with each other along the longitudinal axis within the cavity of the housing.

Abstract: A method for displaying a captured image on a display device. A real image is captured by a vision-based imaging device. A virtual image is generated from the captured real image based on a mapping by a processor. The mapping utilizes a virtual camera model with a non-planar imaging surface. Projecting the virtual image formed on the non-planar image surface of the virtual camera model to the display device.

Abstract: A method for adjusting a vehicle seat for a vehicle is provided. The method includes folding the vehicle seat and displacing the vehicle seat. Folding and displacing are coupled so that on a folding and/or a pushing, the vehicle seat is displaced into a folding position. A vehicle seat and a vehicle are also provided.

Abstract: An inner fender panel for a structural fender of an automotive vehicle is disclosed. The panel includes an outer surface configured for attachment to the inner surface of an outer panel of the fender and an inner surface; the inner panel comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different. A structural fender for an automotive vehicle is also disclosed. The fender includes a formed outer panel having a viewable outer surface and an inner surface. The fender also includes a formed inner fender panel as described comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different.