Abstract: A mirror assembly includes a stem attached to a mirror head. The stem includes a first portion directly attached to the mirror head. The first portion includes a catch. The second portion is attached to a support structure, and includes a retention portion. The catch of the first portion is engaged with the retention portion of the second portion for supporting the first portion and the mirror head relative to the second portion. Once the first portion is supported by the interaction between the catch and the retention portion, fasteners may be installed to fixedly attach the first portion to the second portion.

Abstract: A vehicle door may include a door outer panel defining an exterior surface of the vehicle door; a common door inner panel located inboard of the door outer panel and configured to mount door hardware, with the common door inner panel having a periphery; and a panel extension extending around essentially all of the periphery of the common door inner panel, the panel extension being attached to the periphery of the common door inner panel and attached to the door outer panel to secure the common door inner panel to the door outer panel.

Abstract: A method includes providing a vehicle door having an inner panel, an outer panel, and a bracket assembly. The inner panel and the outer panel cooperate to define a door cavity and a window opening. The bracket assembly is mounted with respect to the inner panel inside the door cavity. The method further includes inserting the division post into the door cavity through the window opening, and engaging the division post with the bracket assembly such that the bracket assembly secures the division post to the inner panel. A corresponding door assembly is also provided.

Abstract: A method of isolating a metallic fastener from a carbon-fiber composite panel includes inserting the metallic fastener within an electrically isolating annular collar; inserting the metallic fastener and electrically isolating annular collar within a hole defined by the carbon-fiber composite panel; and securing the metallic fastener to the carbon-fiber composite panel. The annular collar may be circumferentially disposed about the metallic fastener such that the annular collar separates and electrically isolates the entire metallic fastener from the carbon-fiber composite panel. As such, the annular collar may minimize the galvanic reaction between the fastener and the carbon-fiber composite panel.

Abstract: A modular sunroof frame assembly and method for a vehicle having a body structure is provided. The modular sunroof frame assembly is attachable to the body structure and includes right and left side rails, front and rear cross beams, and a plurality of corner attachment couplings. The right and left side rails have respective cross-sections throughout their length, front rail ends, and rear rail ends. The front and rear cross beams have respective cross-sections throughout their length, right beam ends, and left beam ends. The corner attachment couplings are fixed to the respective side rail end and to the respective cross beam end.

Abstract: A modular sunroof frame assembly and method for a vehicle having a body structure is provided. The modular sunroof frame assembly is attachable to the body structure and includes right and left side rails, front and rear cross beams, and a plurality of corner attachment couplings. The right and left side rails have respective cross-sections throughout their length, front rail ends, and rear rail ends. The front and rear cross beams have respective cross-sections throughout their length, right beam ends, and left beam ends. The corner attachment couplings are fixed to the respective side rail end and to the respective cross beam end.

Abstract: Methods and systems are provided for unlatching a power latch system of a door. In one embodiment, a method includes determining a power mode to be at least one of a primary power mode, a backup power mode, and a series power mode; and selectively controlling power to the power latch system based on the power mode.

Abstract: A vehicle door assembly includes a door inner panel that has a header portion that at least partially defines a window opening. A reinforcement panel is configured to abut the door inner panel along the header portion and further defines the window opening. The door inner panel and the reinforcement panel each have a respective first flange extending at least partially outboard and a respective second flange extending at least partially inboard. The first flange of the door inner panel abuts the first flange of the reinforcement panel and the second flange of the door inner panel abuts the second flange of the reinforcement panel. A trim member is secured to the reinforcement panel and to the header portion to cover the second flanges without contacting the second flanges and has an inboard-facing planar portion as a furthest inboard extent of the trim member.

Abstract: A method includes providing a vehicle door having an inner panel, an outer panel, and a bracket assembly. The inner panel and the outer panel cooperate to define a door cavity and a window opening. The bracket assembly is mounted with respect to the inner panel inside the door cavity. The method further includes inserting the division post into the door cavity through the window opening, and engaging the division post with the bracket assembly such that the bracket assembly secures the division post to the inner panel. A corresponding door assembly is also provided.

Abstract: In accordance with exemplary embodiments, a system for isolating magnesium components from fastener devices is provided to prevent corrosion. The system comprises an isolation member of a metal other than magnesium and configured within a hole for receiving the fastener formed in a magnesium component. A compressible sealing washer having a first diameter is positioned over the hole and an isolation washer having a second diameter being less than the first diameter, and consisting of a similar metal as the isolation member, is placed over the compressible sealing washer. The fastener passes through the isolation washer, the compressible sealing washer and the isolation member within the hole, where is it tightened to compress the compressible sealing washer between the isolation member and isolation washer forming a water-tight seal around the hole to resist corrosion of the magnesium component.

Abstract: A method of isolating a metallic fastener from a carbon-fiber composite panel includes inserting the metallic fastener within an electrically isolating annular collar; inserting the metallic fastener and electrically isolating annular collar within a hole defined by the carbon-fiber composite panel; and securing the metallic fastener to the carbon-fiber composite panel. The annular collar may be circumferentially disposed about the metallic fastener such that the annular collar separates and electrically isolates the entire metallic fastener from the carbon-fiber composite panel. As such, the annular collar may minimize the galvanic reaction between the fastener and the carbon-fiber composite panel.

Abstract: A vehicle door assembly includes a door inner panel that has a header portion that at least partially defines a window opening. A reinforcement panel is configured to abut the door inner panel along the header portion and further defines the window opening. The door inner panel and the reinforcement panel each have a respective first flange extending at least partially outboard and a respective second flange extending at least partially inboard. The first flange of the door inner panel abuts the first flange of the reinforcement panel and the second flange of the door inner panel abuts the second flange of the reinforcement panel. A trim member is secured to the reinforcement panel and to the header portion to cover the second flanges without contacting the second flanges and has an inboard-facing planar portion as a furthest inboard extent of the trim member.

Abstract: Methods and systems are provided for unlatching a power latch system of a door. In one embodiment, a method includes determining a power mode to be at least one of a primary power mode, a backup power mode, and a series power mode; and selectively controlling power to the power latch system based on the power mode.

Abstract: A hemming station is configured for hemming a panel assembly including an outer panel having a hem flange defined by a hem edge. The hemming station includes a roller configured to fold the hem flange, a heating device configured to heat the hem edge, and a control unit. The control unit is configured to control the roller and the heating device such that the roller folds the hem flange when the temperature of the hem edge is in a predetermined temperature range.

Abstract: A lock indicator arm for a door having a latch mechanism includes a rod portion connectable on a first end to the latch mechanism, and a knob portion located on a second end of the rod portion opposite the first end and formed as a one-piece structure with the rod portion. The rod portion may include a spring region configured to bias the rod portion against either an interior panel, an exterior panel, or both panels. The knob portion and the rod portion of the lock indicator arm may be formed from a matrix material and a filler material. The filler material may include a plurality of fibers, and the plurality of fibers may be oriented substantially longitudinally along the rod portion. The rod portion of the lock indicator arm may have one of an H-shape cross section and a W-shape cross section.

Abstract: An obstacle detection system includes a first component and a second component. The motor is configured to move the second component toward the first component. Radio frequency identification tags (RFIDs) are connected to one of the first component and the second component. A controller is operatively connected to the motor and has a transmitter operatively connected to the other of the first component and the second component. The transmitter is operable to create a magnetic field between the first component and the second component. Each of the RFIDs is operable to provide a respective signal in response to the field. The controller is configured to modify power delivery from a power source to the motor when the respective signals received by a receiver change due to at least a portion of the magnetic field being at least partially blocked or attenuated. A method of detecting an obstacle is also provided.

Abstract: An obstacle detection system includes a first component and a second component. The motor is configured to move the second component toward the first component. Radio frequency identification tags (RFIDs) are connected to one of the first component and the second component. A controller is operatively connected to the motor and has a transmitter operatively connected to the other of the first component and the second component. The transmitter is operable to create a magnetic field between the first component and the second component. Each of the RFIDs is operable to provide a respective signal in response to the field. The controller is configured to modify power delivery from a power source to the motor when the respective signals received by a receiver change due to at least a portion of the magnetic field being at least partially blocked or attenuated. A method of detecting an obstacle is also provided.

Abstract: A vehicle door may include a door outer panel defining an exterior surface of the vehicle door; a common door inner panel located inboard of the door outer panel and configured to mount door hardware, with the common door inner panel having a periphery; and a panel extension extending around essentially all of the periphery of the common door inner panel, the panel extension being attached to the periphery of the common door inner panel and attached to the door outer panel to secure the common door inner panel to the door outer panel.

Abstract: In accordance with exemplary embodiments, a system for isolating magnesium components from fastener devices is provided to prevent corrosion. The system comprises an isolation member of a metal other than magnesium and configured within a hole for receiving the fastener formed in a magnesium component. A compressible sealing washer having a first diameter is positioned over the hole and an isolation washer having a second diameter being less than the first diameter, and consisting of a similar metal as the isolation member, is placed over the compressible sealing washer. The fastener passes through the isolation washer, the compressible sealing washer and the isolation member within the hole, where is it tightened to compress the compressible sealing washer between the isolation member and isolation washer forming a water-tight seal around the hole to resist corrosion of the magnesium component.

Abstract: Presented here is an electrical system for a vehicle having an electrical load. The electrical system includes a primary energy source, a rechargeable redundant energy source coupled to the primary energy source via a first switch, a second switch, a third switch, a fourth switch, and a control unit. The fourth switch is coupled between the electrical load and the second switch, and is coupled between the electrical load and the third switch. The control unit operates the first switch to facilitate charging of the rechargeable redundant energy source with the primary energy source, operates the second switch and the third switch in concert to selectively provide operating power from either the primary energy source or the rechargeable redundant energy source to the fourth switch, and operates the fourth switch to provide the operating power to the electrical load.