Abstract: Methods of producing continuous carbon fibers for composites having enhanced moldability are provided. Discrete regions are introduced into a continuous precursor fiber comprising an acrylic polymer material, such as polyacrylonitrile (PAN), as the precursor fiber is formed. The precursors may be heterogeneous fibers having a second distinct material interspersed in discrete regions with the acrylic polymer material. Alternatively, the precursors may be heterogeneous fibers where laser is applied to the acrylic polymer material in discrete regions to cause localized molecular disruptions. After the continuous precursor fiber is heated for carbonization and/or graphitization, the precursor forms a continuous carbon fiber having a plurality of discrete weak regions. These relatively weak regions provide noncontiguous break points that reduce stiffness and improve moldability for carbon fiber polymeric composites, while retaining high strength levels.

Abstract: Methods of producing continuous carbon fibers for composites having enhanced moldability are provided. Discrete regions are introduced into a continuous precursor fiber comprising an acrylic polymer material, such as polyacrylonitrile (PAN) during carbon fiber manufacture. Laser energy may be applied to the precursor fiber while it is in an oven or furnace to create heterogeneous fibers with discrete regions where laser energy is applied. In other aspects, mechanical pressure may be intermittently applied to create the discrete regions. After the continuous precursor fiber is fully heated for carbonization and/or graphitization, the precursor forms a continuous carbon fiber having a plurality of discrete weak regions. These relatively weak regions provide noncontiguous break points that reduce stiffness and improve moldability for carbon fiber polymeric composites, while retaining high strength levels.

Abstract: In an example of a method for making a bi-layer separator, a polymer solution is coated on a sacrificial support or a carrier belt to form a polymer solution layer. A porous membrane is established on the polymer solution layer. At least some of the polymer solution layer is solidified to form a porous polymer coating adjacent to the porous membrane. The porous polymer coating and the porous membrane together form the bi-layer separator.

Abstract: Methods for making battery electrode system are disclosed herein. In an example of the method, a mixture of a polymer binder, an active material and a conductive filler is deposited on a current collector. The deposited mixture is exposed to an external field having a field direction that is normal to a surface of the current collector. The exposure aligns, outward from and normal to the surface of the current collector, the active material and the conductive filler to form a plurality of discrete structures that extend outward from and normal to the surface of the current collector and are respectively aligned with a field line of the external field. Each of the plurality of discrete structures includes some of the active material and some of the conductive filler.

Abstract: A porous polymer battery separator includes variable porosity along its length and can increase the uniformity of the current density within electrochemical battery cells that may normally experience higher current density and higher temperatures near their terminal ends than they do near their opposite ends. By disposing a variable porosity separator between the electrodes of an electrochemical cell such that its terminal end has a lower porosity than its opposite end, the transport of ions through the separator can be more restricted in normally high current regions and less restricted in normally low current regions, thereby increasing the overall uniformity of current density within the cell. The separators may be produced by a dry-stretching process or by a wet process. These processes may include forming a polymer-containing film, producing a uniform distribution of pore sites within the film, and reforming the polymer-containing film to a uniform thickness.

Abstract: A separator includes a non-woven substrate. The non-woven substrate includes a first and a second side. An adhesive coating is disposed on the first side, the second side, or both the first and second sides of the non-woven substrate. The adhesive coating is a surfactant. A porous polymer layer is disposed on the adhesive coating such that the adhesive coating forms an intermediate layer between the non-woven substrate and the porous polymer layer.

Abstract: A wheel impact sensing system of a vehicle includes at least one sensor measuring an acceleration of a vehicle wheel resulting from an impact to the vehicle wheel. A processor determines a severity of the impact to the vehicle wheel as function of the acceleration measurement. An output device alerts a driver to potential damage of the vehicle wheel based on the determined impact severity to the vehicle wheel.

Abstract: A porous bi-layer separator is composed of a first separator layer with a contacting array of non-conducting particles overlaid with a second separator layer of a microporous polymer layer, fabricated on the electrode surface of the anode of a lithium-ion battery to form an integral electrode-separator construction. Exemplary bi-layer separators may be fabricated by deposition of solvent-containing slurries of separator particles followed by solvent evaporation to produce the particle layer with subsequent application of polymer solutions followed by controlled evaporation of solvent to produce the microporous polymer layer. The elevated temperature performance of lithium-ion battery cells incorporating such integral electrode-bi-layer separators was demonstrated to exceed the performance of similar cells using commercial and experimental single layer polymer separators.

Abstract: Application of carbon fiber reinforced polymer structures to metal vehicle wheels is effective in reducing the mass of the wheel while retaining suitable stiffness in the wheel structure. For maximum effect the reinforced polymer structure and the metal wheel must operate cooperatively. Because of the wide range of operating temperatures experienced by wheels and the large difference in coefficient of thermal expansion between metals and carbon fiber reinforced composites attachment of the polymer structure to the wheel by adhesive alone is problematical. However a wheel with an effective and durable reinforcement may be fabricated by confining, through mechanical interference, the reinforced polymer in a cavity in or on the spoke and by preheating the wheel before curing the polymer.

Abstract: A product, and a method for forming a product, that includes a composite material having a polymeric carrier resin and a shape memory polymer material capable of transformation between a temporary shape and a permanent shape in the presence of an external stimuli, wherein said transformation from said temporary shape to said permanent shape changes at least one property of said composite material.

Abstract: A fender bracket includes a composite structure having a first flange to operatively connect to a fender, a second flange to operatively connect to a vehicle body structure, and a web connecting the first flange and the second flange. At least one actuator is positioned in at least a portion of the web. The at least one actuator is selected from a piezoelectric actuator, an active material actuator, and a pyrotechnic actuator. The at least one actuator is to cause a fracture or buckling of the web in response to an activation signal.

Abstract: The present technology discloses a system, for joining workpieces using energy, such as ultrasonic energy, where the energy concentrates at a location within a weld area, promoting sequential melting of a plurality of energy directors. The system can be configured so that the sequential melting begins at the center of the weld area and progresses outwards. Sequential melting may occur through use of a welding tip configured to reduce air pockets, a tapering the height of a plurality of energy directors, and/or tapering the energy directors themselves, all of which reduce the size of an energy transfer area produced by thermal energy. The present technology also includes a method for joining workpieces using energy such as ultrasonic energy that concentrates at a location within a weld area causing sequential melting of a plurality of energy directors using the aforementioned features.

Abstract: A method for forming integral separator-electrodes for a battery. The method comprises providing a continuous electrode sheet having an electrode active material deposited on a current collector. The method includes forming a plurality of individual electrodes from the continuous electrode sheet. Each electrode is formed having a center region and a plurality of edges. A separator coating having a substantially uniform thickness is applied to the center region and the plurality of edges of each electrode. The separator coating layer is larger in size than the electrode active material coated area.

Abstract: Methods for minimizing thermal expansion in an assembly, e.g., a bearing assembly, for a vehicle are provided. The assembly has at least two components with substantially different linear coefficients of thermal expansion (CLTEs). The assembly has a polymeric composite with a first CLTE, a lightweight metal component (e.g., a housing) with a second CLTE, and a third component (e.g., a bearing component) having a third CLTE. The second CLTE is ?25% more than the third CLTE. The first CLTE is less than or equal to the third CLTE, so that the polymeric composite structure coupled to the first surface reduces radial thermal expansion of the first metal component and minimizes separation of the second surface of the first metal component from the second component.

Abstract: A lightweight spare tire system. The lightweight spare tire system includes a carbon fiber composite vehicle rim that is suitable for use with a spare tire and a lightweight tire that is suitable for use with the carbon fiber composite rim. The lightweight tire and rim creates a lightweight spare wheel that may be used on a vehicle.

Abstract: A method of mitigating galvanic corrosion on a vehicle is provided for use of metals with carbon containing composites. An electrically conductive material comprising a plurality of electrically conductive metallic particles and a polymer is applied to a corrosion susceptible region of an assembly having a carbon-reinforced composite and a metal. The electrically conductive material has an electrical conductivity of greater than or equal to about 1×10?4 S/m and serves as a sacrificial anode to mitigate or prevent corrosion of the metal in the assembly. Also provided are assemblies for a vehicle having reduced galvanic corrosion that include a metal component in contact with a carbon-reinforced composite, which defines a corrosion susceptible region having an electrically conductive material disposed therein.

Abstract: A porous bi-layer separator is composed of a first separator layer with a contacting array of non-conducting particles overlaid with a second separator layer of a microporous polymer layer, fabricated on the electrode surface of the anode of a lithium-ion battery to form an integral electrode-separator construction. Exemplary bi-layer separators may be fabricated by deposition of solvent-containing slurries of separator particles followed by solvent evaporation to produce the particle layer with subsequent application of polymer solutions followed by controlled evaporation of solvent to produce the microporous polymer layer. The elevated temperature performance of lithium-ion battery cells incorporating such integral electrode-bi-layer separators was demonstrated to exceed the performance of similar cells using commercial and experimental single layer polymer separators.

Abstract: A one-piece fiber reinforcement for a reinforced polymer is described. In an embodiment, a one-piece reinforcement is fabricated by first assembling an interior randomly oriented fiber layer between two exterior aligned fiber layers. With all layers in face to face contact, a preselected number of fibers from the aligned layer is conveyed out of its aligned layer and threaded into at least the random fiber layer so that the conveyed fibers engage and mechanically and frictionally interfere with the random fibers. The fibers may be conveyed from one aligned layer to the other for yet greater interference. The interfering fibers serve to secure and interlock the layers together, producing a one-piece reinforcement which, when impregnated with a polymer precursor, shaped and cured may be incorporated in a polymer reinforced composite article.

Abstract: A method of repairing a polymeric composite workpiece. The method includes detecting and identifying a localized area of a polymeric composite workpiece having a defect. A resin is applied to the localized area. The resin includes a plurality of magnetic particles dispersed therein. The resin may include a mixture of nanoparticles dispersed therein, selected from the group consisting of a thermosetting resin, a thermoplastic resin, and mixtures thereof. The method includes introducing radiofrequency electromagnetic radiation adjacent the resin to selectively induce localized heating and/or curing of the resin.

Abstract: Methods for minimizing thermal expansion in an assembly, e.g., a bearing assembly, for a vehicle are provided. The assembly has at least two components with substantially different linear coefficients of thermal expansion (CLTEs). The assembly has a polymeric composite with a first CLTE, a lightweight metal component (e.g., a housing) with a second CLTE, and a third component (e.g., a bearing component) having a third CLTE. The second CLTE is ?25% more than the third CLTE. The first CLTE is less than or equal to the third CLTE, so that the polymeric composite structure coupled to the first surface reduces radial thermal expansion of the first metal component and minimizes separation of the second surface of the first metal component from the second component.