Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure.

Abstract: A method of forming at least one channel within a substrate includes coupling a fitting to a mold, and securing together the fitting and an insert via threads. A system includes a mold configured to form the substrate. The method also includes inserting a component into an opening of the fitting. Part of the component is disposed outside of the opening of the fitting, and the component is utilized to define the at least one channel within the substrate. The method further includes molding at least one material to the component and the insert to form the substrate. Furthermore, the method includes removing the fitting from the insert while the insert remains molded to the substrate.

Abstract: Systems, methods, and high performance electrochemical devices employing electroactive particles having a sandwich structure are described. The electroactive particle includes an electroactive layer between a pair of dimension-control layers. The electroactive layer includes an electroactive material configured to receive cations and experience a volumetric change in response thereto. The dimension-control layers are configured to inhibit planar dimensional changes of the electroactive particle such that the volumetric change of the electroactive layer occurs through a vertical dimension of the electroactive particle. The vertical dimension is orthogonal to the planar dimensions.

Abstract: An apparatus for perforating a carbon fiber substrate material comprises a support structure including a first side support and a second side support and a cylindrical anvil rotatably connected between the first side support and the second side support. The anvil is configured to move the carbon fiber substrate material in response to rotation of the anvil. The apparatus further comprises a cylindrical cutting wheel rotatably connected to the support structure between the first side support and the second side support and positioned adjacent to the anvil. The cutting wheel includes a plurality of blades projecting outward from an outer surface of the cutting wheel wherein the blades of the cutting wheel are configured to perforate the carbon fiber substrate material when the carbon fiber substrate material moves between the anvil and the cutting wheel.

Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure.

Abstract: A connecting rod includes a shank extending along a shank axis and a first end portion coupled to the shank. The first end portion has an annular shape. The connecting rod also includes a second end portion coupled to the shank. The second end portion has an annular shape. Each of the shank, the first end portion, and the second end portions includes a fiber-reinforced composite. The fiber-reinforced composite includes a matrix and a plurality of fibers embedded in the matrix. At least one of the shank fibers is elongated along the shank axis.

Abstract: A running board configured for absorbing energy includes an attachment portion extending along a longitudinal axis and a step-assist portion extending from the attachment portion along a latitudinal axis that is perpendicular to the longitudinal axis. The attachment portion defines a plurality of voids therein each disposed along a respective one of a plurality of horizontal axes that are perpendicular to the longitudinal axis. The running board further includes a plurality of tubes disposed within a respective one of the plurality of voids. A device including the running board and a method of forming a running board are also set forth.

Abstract: Presented are manufacturing control systems for composite-material structures, methods for assembling/operating such systems, and transfer molding techniques for predicting and ameliorating void conditions in fiber-reinforced polymer panels. A method for forming a composite-material construction includes receiving a start signal indicating a fiber-based preform is inside a mold cavity, and transmitting a command signal to inject pressurized resin into the mold to induce resin flow within the mold cavity and impregnate the fiber-based preform. An electronic controller receives, from a distributed array of sensors attached to the mold, signals indicative of pressure and/or temperature at discrete locations on an interior face of the mold cavity. The controller determines a measurement deviation between a calibrated baseline value and the pressure and/or temperature values for each of the discrete locations.

Abstract: Systems, methods, and high performance electrochemical devices employing electroactive particles having a sandwich structure are described. The electroactive particle includes an electroactive layer between a pair of dimension-control layers. The electroactive layer includes an electroactive material configured to receive cations and experience a volumetric change in response thereto. The dimension-control layers are configured to inhibit planar dimensional changes of the electroactive particle such that the volumetric change of the electroactive layer occurs through a vertical dimension of the electroactive particle. The vertical dimension is orthogonal to the planar dimensions.

Abstract: A thermally-stable composite separator for an electrochemical cell that cycles lithium ions is provided, along with methods of making the composite separator. The method includes contacting one or more surface regions of a coated substrate with a coagulant. The coated substrate includes an insulating porous substrate and at least one non-porous polymeric layer including a polymer, one or more nanoparticles, one or more sub-micron particles, and a solvent. Contacting the coated substrate with the coagulant medium removes the solvent causing the polymer to precipitate forming at least one substantially uniform porous polymer layer in place of the at least one non-porous polymeric layer. The coagulant medium has a viscosity greater than that of the solvent and a solubility parameter distance between the polymer and the coagulant medium is less than that between the polymer and water.

Abstract: Methods for pre-lithiating an anode include providing the anode having a host material comprising silicon particles or SiOx particles, disposing a first side of an electrically conductive pre-lithiating separator contiguous with the anode, and disposing a lithium source contiguous with a second side of the pre-lithiating separator such that lithium ions migrate to the host material via the pre-lithiating separator. The pre-lithiating separator comprises a porous body, one or more solvents, and one or more lithium ions. Method for manufacturing a battery cell, further include separating the pre-lithiating separator from the lithiated anode, and combining the lithiated anode with a battery separator and a lithium cathode to form a battery cell. The methods can further include applying a voltage to the anode and the lithium source, or maintaining a constant current between the lithium source and the anode while lithium ions migrate to the host material.

Abstract: A running board configured for absorbing energy includes an attachment portion extending along a longitudinal axis and a step-assist portion extending from the attachment portion along a latitudinal axis that is perpendicular to the longitudinal axis. The attachment portion defines a plurality of voids therein each disposed along a respective one of a plurality of horizontal axes that are perpendicular to the longitudinal axis. The running board further includes a plurality of tubes disposed within a respective one of the plurality of voids. A device including the running board and a method of forming a running board are also set forth.

Abstract: An energy-absorbing assembly includes a first component and a second component. The first component includes a first polymer and a first plurality of reinforcing fibers. The first component includes a first peripheral wall defining a first interior compartment. A first interior portion of the first peripheral wall includes a first corrugated surface. A second component includes a second polymer and a second plurality of reinforcing fibers. The second component includes a second peripheral wall. A second interior portion of the second peripheral wall includes a second corrugated surface. The first corrugated surface is complementary to the second corrugated surface. The first corrugated surface is joined to the second corrugated surface.

Abstract: Methods of producing a continuous carbon fiber for use in composites having enhanced moldability are provided. A continuous precursor fiber is formed that has a sheath and a core. The sheath includes a first polymer material. The core includes a second polymer material and a plurality of discrete regions distributed within the second polymer material. The discrete regions include a third polymer material. After the continuous precursor fiber is heated for carbonization and graphitization, the continuous precursor fiber forms a continuous carbon fiber having a plurality of discrete weak regions corresponding to the plurality of discrete regions in the core. Carbon fiber composites made from such modified continuous carbon fibers having enhanced moldability are also provided.

Abstract: Methods of repairing a manufacturing defect in a molded polymeric composite structure are provided. A polymeric patch may optionally be disposed over a defect on a first contoured surface of the molded polymeric composite structure having the defect. A heating element that defines a second contoured surface complementary with at least a portion of the first contoured surface is applied over the polymeric patch. The heating element includes an electrically conductive layer that includes a fabric and a thermoset polymer. The polymeric patch is heated with the heating element, where the heating element has a substantially uniform temperature across the second contoured surface so that the polymeric patch fills the defect. Methods of making the customized heating elements and the customized heating elements are also provided.

Abstract: A power module according to various aspects of the present disclosure includes a housing and a thermally-conductive element. The housing includes a polymer. The housing at least partially defines a channel. The channel is configured to receive a fluid. The thermally-conductive element is disposed at least partially within the housing. The thermally-conductive element is in fluid communication with the channel. The thermally-conductive element includes a thermally-conductive material. The thermally-conductive element is in thermal communication with the channel and a heat source. In certain aspects, includes at least one of a protrusion, a pin, and sheath. A method of manufacturing a channel having a thermally-conductive element for heat transfer includes (a) forming a channel, (b) forming a housing, and (c) removing a sacrificial material.

Abstract: A cylinder head assembly for an engine assembly is provided herein. The cylinder head assembly may include a head framework, an exhaust liner include a thermal barrier material, an intake liner, and a polymeric housing disposed around at least a portion of the metal head framework and the exhaust liner. The cylinder head assembly may further include a plurality of channels for heating and/or cooling the cylinder head assembly, which can be defined in one or more of: the metal head framework, the exhaust liner, and the polymeric housing. Methods of making the cylinder head assembly are also provided herein.

Abstract: A connecting rod includes a shank formed of a composite. The connecting rod also includes a first end portion coupled to the shank and a second end portion coupled to the shank. The first end portion has an annular shaped portion, and the second end portion has an annular shaped portion. The shank defines a channel coupled to the first and second end portions. A method of manufacturing a connecting rod includes placing a plurality of fibers in a predetermined arrangement, and adding a resin to the plurality of fibers to connect the fibers together and form a composite of at least a shank. The method also includes disposing a component inside the shank, and the component is utilized to define a channel in the shank. The method further includes coupling a first end portion to the shank, and coupling a second end portion to the shank.

Abstract: A method of forming at least one channel within a substrate includes coupling a fitting to a mold, and securing together the fitting and an insert via threads. A system includes a mold configured to form the substrate. The method also includes inserting a component into an opening of the fitting. Part of the component is disposed outside of the opening of the fitting, and the component is utilized to define the at least one channel within the substrate. The method further includes molding at least one material to the component and the insert to form the substrate. Furthermore, the method includes removing the fitting from the insert while the insert remains molded to the substrate.

Abstract: An energy-absorbing structure includes first and second components. The first component includes a polymer and a plurality of reinforcing fibers disposed therein. The first component includes first bumper and crush member portions respectively defined by first and second walls. The second wall projects from and is integrally formed with the second wall. At least some of the fibers continuously extend between the first and second walls. The second component includes the polymer and a plurality of reinforcing fibers. The second component includes second bumper and crush member portions respectively defined by third and fourth walls. The fourth wall projects from and is integrally formed with the third wall. At least some of the fibers continuously extend between the third and fourth walls. The first and second components are joined. The first and third walls cooperate to define a bumper. The second and fourth walls cooperate to define a crush member.