Abstract: A process for molding a composite unipolar plate for a fuel cell stack that increases the strength of a header region of the plate. High strength, non-conductive prepeg inserts are positioned within the mold that are shaped to the configuration of the header region, including the openings that define the various inlet and outlet manifolds. A bulk molding compound charge is positioned in the mold and pressed under high heat so that the bulk molding compound disperses in the mold, and covers the prepeg inserts so that the prepeg inserts are cured to the bulk molding compound.

Abstract: A method disclosed herein includes packaging and de-packaging a part. The part is packaged by placing the part adjacent to a shape memory polymer (SMP) while the SMP is in a permanent shape. The SMP is heated to a temperature above a switching temperature of the SMP, and a force is applied to the heated SMP such that it conforms to i) a shape of the part and/or ii) a desired shape for packing the part, thereby changing the SMP from the permanent shape into a temporary shape. The SMP is cooled to a temperature below the switching temperature to set the SMP into the temporary shape. The part is de-packaged by heating the SMP to a temperature above its switching temperature, thereby reverting the SMP from the temporary shape into the permanent shape and releasing the part. The part is removed from the SMP in the permanent shape.

Abstract: Magnesium alloy tube members have the potential to reduce weight in automotive vehicle body structures and other applications but they tend to fragment and fail under compressive stress loads applied end-to-end along the longitudinal axis of the tube. It is found that, when the outside surface of the tube is tightly wrapped with fibers (for example, glass fibers or other suitable fibers) and, optionally, resin bonded to the tube surface, the capacity of the magnesium alloy tube to withstand and absorb compressive loads is greatly increased.

Abstract: A medical cast and methods of using the same are disclosed. The method of making includes providing a shape memory polymer (SMP) in a permanent shape which corresponds to a limb's general shape but has a diameter smaller than the limb's diameter. The SMP is converted from the permanent shape into a primary temporary shape, which has a diameter larger than both a diameter of the permanent shape and a diameter of the limb. The limb is at least partially surrounded with the SMP in its primary temporary shape. The SMP is then heated, which causes the primary temporary shape to i) attempt to revert to the permanent shape, and ii) conform to a secondary temporary shape having a diameter smaller than that of the primary temporary shape and larger than that of the permanent shape. The SMP in the secondary temporary shape conforms to the limb.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution separator plate assembly, a method of making, and a system for using, the electrically conductive fluid distribution separator plate assembly. In at least one embodiment, the electrically conductive fluid distribution separator plate assembly comprises a metallic cathode plate having opposed surfaces and a first contact resistance, a polymeric composite anode plate adjacent to the metallic cathode plate, and a low contact resistance coating located on at least one of the surfaces of the plates, with the coating having a second contact resistance, less than the first contact resistance.

Abstract: One method of forming a part includes deforming a shape memory polymer from a permanent shape into a temporary shape, where the permanent shape of the shape memory polymer is a predetermined part shape and the temporary shape is a shape larger than the predetermined part shape. The shape memory polymer in each of the permanent shape and the temporary shape defines a cavity therein. The method further includes introducing a molding material into the cavity of the shape memory polymer, and reverting the shape memory polymer back into its permanent shape. Other methods for forming the part are also disclosed herein.

Abstract: A door assembly for a vehicle includes an outer panel. A support panel is operatively connected to the outer panel and configured such that the support panel provides bending resistance to the outer panel when the outer panel is deflected toward the support panel during a first deflection distance of the outer panel. A cable is operatively connected in the door assembly between a first end and a second end of the outer panel such that the cable provides additional bending resistance to the outer panel when the outer panel is deflected toward the support panel during a second deflection distance of the outer panel, greater than the first deflection distance.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution separator plate assembly, a method of making, and a system for using, the electrically conductive fluid distribution separator plate assembly. In at least one embodiment, the electrically conductive fluid distribution separator plate assembly comprises a metallic cathode plate having opposed surfaces and a first contact resistance, a polymeric composite anode plate adjacent to the metallic cathode plate, and a low contact resistance coating located on at least one of the surfaces of the plates, with the coating having a second contact resistance, less than the first contact resistance.

Abstract: A method for making a preform includes creating a pressure differential between an inside and an outside of a perforated shape memory polymer mandrel in its temporary shape. The pressure differential is such that pressure outside the perforated shape memory polymer mandrel is greater than pressure inside the perforated shape memory polymer mandrel. The perforated shape memory polymer mandrel has i) a predetermined preform shape as the temporary shape and ii) a shrunken shape as its permanent shape, wherein the shrunken shape is configured such that it is removable from the predetermined preform shape. The method further includes depositing, as the pressure differential is maintained, at least one material onto a surface of the perforated shape memory polymer mandrel. The at least one material is set in the predetermined preform shape, thereby forming the preform.

Abstract: Compositions including a base resin, a reinforcement and a modifier including a block copolymer for producing vesicles, spherical and/or cylindrical micelles and composites made therefrom.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution separator plate assembly, a method of making, and a system for using, the electrically conductive fluid distribution separator plate assembly. In at least one embodiment, the electrically conductive fluid distribution separator plate assembly comprises a metallic cathode plate having opposed surfaces and a first contact resistance, a polymeric composite anode plate adjacent to the metallic cathode plate, and a low contact resistance coating located on at least one of the surfaces of the plates, with the coating having a second contact resistance, less-than the first contact resistance.

Abstract: A vent assembly is disposed within an interior space of a vehicle for opening and closing fluid communication between the interior space and an exterior of the vehicle. The vent assembly includes a housing defining a plurality of openings and a plurality of vanes disposed in the openings. An actuator mechanism moves the vanes between an open position and a closed position, and includes a shaped memory alloy (SMA) member for actuating the vanes between the open and closed positions. The SMA member is activated when a hatch of the vehicle is open to move the vanes into the open position and thereby open fluid communication between the interior space and the exterior to alleviate excessive air pressure buildup during closure of the hatch.

Abstract: Packaging and de-packaging methods using shape memory polymers are disclosed herein. An embodiment of the packaging method involves placing a part adjacent to shape memory polymer in its permanent shape, heating the shape memory polymer to a temperature above its switching temperature, and applying a force to the heated shape memory polymer such that the polymer switches from its permanent shape into a temporary shape. The temporary shape of the shape memory polymer conforms to at least one of i) a shape of the part, or ii) a desired shape for packaging the part. The method further includes cooling the shape memory polymer to a temperature below its switching temperature to set the temporary shape.

Abstract: One exemplary embodiment of an anti-intrusion beam for a vehicle door assembly may include a composite material. The composite material includes a fiber reinforcement with multiple fibers. The fibers may be oriented at an angle ranging between about 35 and 55 degrees when measured with respect to a lengthwise dimension of the anti-intrusion beam.

Abstract: One exemplary embodiment of an anti-intrusion beam for a vehicle door assembly may include a composite material. The composite material includes a fiber reinforcement with multiple fibers. The fibers may be oriented at an angle ranging between about 35 and 55 degrees when measured with respect to a lengthwise dimension of the anti-intrusion beam.

Abstract: A medical cast and methods of using the same are disclosed. The method of making includes providing a shape memory polymer (SMP) in a permanent shape which corresponds to a limb's general shape but has a diameter smaller than the limb's diameter. The SMP is converted from the permanent shape into a primary temporary shape, which has a diameter larger than both a diameter of the permanent shape and a diameter of the limb. The limb is at least partially surrounded with the SMP in its primary temporary shape. The SMP is then heated, which causes the primary temporary shape to i) attempt to revert to the permanent shape, and ii) conform to a secondary temporary shape having a diameter smaller than that of the primary temporary shape and larger than that of the permanent shape. The SMP in the secondary temporary shape conforms to the limb.

Abstract: One method of forming a part includes deforming a shape memory polymer from a permanent shape into a temporary shape, where the permanent shape of the shape memory polymer is a predetermined part shape and the temporary shape is a shape larger than the predetermined part shape. The shape memory polymer in each of the permanent shape and the temporary shape defines a cavity therein. The method further includes introducing a molding material into the cavity of the shape memory polymer, and reverting the shape memory polymer back into its permanent shape. Other methods for forming the part are also disclosed herein.

Abstract: A method includes providing a shape memory polymer in a permanent shape, where the permanent shape is at least part of a predetermined part shape, converting the shape memory polymer from the permanent shape into a temporary shape, where the temporary shape is more open than the permanent shape. The method further includes spraying a material onto at least one surface of the shape memory polymer in its temporary shape and reverting the shape memory polymer, having the material on the at least one surface, back to the permanent shape.

Abstract: A method for making a preform includes creating a pressure differential between an inside and an outside of a perforated shape memory polymer mandrel in its temporary shape. The pressure differential is such that pressure outside the perforated shape memory polymer mandrel is greater than pressure inside the perforated shape memory polymer mandrel. The perforated shape memory polymer mandrel has i) a predetermined preform shape as the temporary shape and ii) a shrunken shape as its permanent shape, wherein the shrunken shape is configured such that it is removable from the predetermined preform shape. The method further includes depositing, as the pressure differential is maintained, at least one material onto a surface of the perforated shape memory polymer mandrel. The at least one material is set in the predetermined preform shape, thereby forming the preform.

Abstract: A method of forming a part with a feature having a die-locked geometry is disclosed herein. A molding tool used in the method includes at least one die having a cavity defined in a surface thereof, and a protrusion formed in the cavity. The method includes disposing a shape memory polymer insert on the protrusion, where the shape memory polymer insert has i) the die-locked geometry as its temporary shape, and ii) a geometry that is removable from the die-locked geometry as its permanent shape. A material is established in the cavity such that at least a portion of the material conforms to the die-locked geometry, thereby forming the part having the feature with the at least one die-locked geometry.