Abstract: An automotive structural component includes a lattice structure. The lattice structure defines a plurality of cells. The plurality of cells include a multitude of at least partially filled cells each at least partially filled with a filling, and a multitude of hollow cells distributed amongst the multitude of at least partially filled cells to distribute and direct load.

Abstract: A number of variations may include a product that may include a part that may include a composite material that may include a plurality of tubes that may include a plurality of fibers arranged in a generally tubular shape and having at least two sizings temporarily capping the ends of the plurality of tubes and containing a resin.

Abstract: A system and method for bonding structures includes a method of bonding a first panel to a second panel. An adhesive material is applied to at least one of the first panel and the second panel and is disposed between the first panel and the second panel. A welding device having at least a first electrode and a second electrode is configured to receive and position the first panel and second panel between the first and second electrodes. The welding device generates an electric current with the first and second electrodes to apply to the first panel and the second panel. The electric current generates thermal energy having a first temperature that cures the adhesive material positioned between the first and second electrodes to bond the first panel with the second panel.

Abstract: Disclosed are metalworking rollers for fabricating multi-gauge sheet metal parts, methods for making and methods for using such rollers, and rolling mill machines employing variable-radius metalworking rollers for fabricating multi-gauge metal components. A metalworking roller for a rolling mill machine is disclosed. The metalworking roller includes a cylindrical roller body that rotatably and drivingly connects to the rolling mill machine. An outer diameter surface spanning around the roller body circumference includes an outermost peak region and an innermost valley region recessed radially inward from the outermost peak region and elongated circumferentially around the roller body. During operation of the rolling mill machine, the outermost and innermost regions of the roller body's outer diameter surface sequentially press against and thereby modify the gauge of a metal workpiece.

Abstract: A vehicle having a power-source configured to propel the vehicle via power-source torque, a driven wheel configured to receive the power-source torque, and a vehicle body structure. The vehicle body structure includes a wheelhouse configured to extend over the driven wheel and also defines a locating feature. The vehicle further includes an integrated weight element configured to engage the locating feature and a fastener configured to fix the integrated weight element to the vehicle body structure either proximate to or directly to the wheelhouse. The vehicle can be configured as a truck, wherein the vehicle body structure includes a truck bed incorporating the wheelhouse and the integrated weight element.

Abstract: A vehicle having a power-source configured to propel the vehicle via power-source torque, a driven wheel configured to receive the power-source torque, and a vehicle body structure. The vehicle body structure includes a wheelhouse configured to extend over the driven wheel and also defines a locating feature. The vehicle further includes an integrated weight element configured to engage the locating feature and a fastener configured to fix the integrated weight element to the vehicle body structure either proximate to or directly to the wheelhouse. The vehicle can be configured as a truck, wherein the vehicle body structure includes a truck bed incorporating the wheelhouse and the integrated weight element.

Abstract: A number of variations may include a method that may include providing a composite material that may include nano-tubes that may include pressure activated resin, forming the composite material such that the resin within the nano-tubes may begin to cure, holding the composite material in a formed state, removing the composite material from the formed state, and curing the composite material.

Abstract: A vehicle structural member, such as a rocker panel, including a micro-truss core. The structural member includes specially configured and opposing outer panels that are welded together to define a channel therein, where the micro-truss core is placed in one of the panels or is fabricated to one of the panels during the micro-truss fabrication process before the panels are secured together. The micro-truss core can include separate individual sections, where each section has a tailored stiffness for that location in the member, or the micro-truss core can be a continuous core, where different sections along the length of the core are fabricated with different stiffnesses.

Abstract: A number of variations may include a product that may include a part that may include a composite material that may include a plurality of tubes that may include a plurality of fibers arranged in a generally tubular shape and having at least two sizings temporarily capping the ends of the plurality of tubes and containing a resin.

Abstract: A method of joining a first thermoplastic component with a second thermoplastic component includes abutting a joint surface of the first thermoplastic component against a joint surface of the second thermoplastic component. The first thermoplastic component includes a thermoplastic protrusion extending from the joint surface, and the joint surface of the second thermoplastic component defines a receiving pocket adapted to receive the thermoplastic protrusion. Abutting a joint surface of the first thermoplastic component against a joint surface of the second thermoplastic component further includes inserting the thermoplastic protrusion into the receiving pocket. Once abutted, thermal energy is applied to a heat-apply surface of the second thermoplastic component, that is opposite the joint surface. The thermal energy is sufficient to melt a portion of the thermoplastic protrusion and a portion of the joint surface of the second thermoplastic component.

Abstract: A number of variations may include a method that may include providing a composite material that may include nano-tubes that may include pressure activated resin, forming the composite material such that the resin within the nano-tubes may begin to cure, holding the composite material in a formed state, removing the composite material from the formed state, and curing the composite material.

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 structural member, such as a rocker panel, including a micro-truss core. The structural member includes specially configured and opposing outer panels that are welded together to define a channel therein, where the micro-truss core is placed in one of the panels or is fabricated to one of the panels during the micro-truss fabrication process before the panels are secured together. The micro-truss core can include separate individual sections, where each section has a tailored stiffness for that location in the member, or the micro-truss core can be a continuous core, where different sections along the length of the core are fabricated with different stiffnesses.

Abstract: A method of bonding a first panel made of a first material to a second panel made of a second material is provided. The method includes creating a second panel hole in the second panel at a weld location. An insert composed of the first material is inserted into the second panel hole in the second panel. At least a portion of the insert is fittable in the second panel hole and sized to correspond to the second panel hole. The first panel and the insert are welded together at the weld location, thereby bonding the first and second panels. In one embodiment, the first and second panels are placed between the first and second electrodes of a welding gun. A force is applied to clamp the insert and the first panel between the first and second electrodes and a welding current is delivered. A bonded structure is provided.

Abstract: A number of variations may include a method may include providing a first part and a second part and forming a first plurality of prolongations on a surface of the first part and forming a second plurality of prolongations on a surface of the second part. The first part and the second part may be brought together and abutted such that the first plurality of prolongations abuts against the second plurality of prolongations. The first plurality of prolongations and the second plurality of prolongations may be constructed and arranged to mechanically bond. A load may be applied such that both the first plurality of prolongations and second plurality of prolongations temporarily deform and mechanically bond the first part and the second part together.

Abstract: A method of bonding a first panel made of a first material to a second panel made of a second material is provided. The method includes creating a second panel hole in the second panel at a weld location. An insert composed of the first material is inserted into the second panel hole in the second panel. At least a portion of the insert is fittable in the second panel hole and sized to correspond to the second panel hole. The first panel and the insert are welded together at the weld location, thereby bonding the first and second panels. In one embodiment, the first and second panels are placed between the first and second electrodes of a welding gun. A force is applied to clamp the insert and the first panel between the first and second electrodes and a welding current is delivered. A bonded structure is provided.

Abstract: A structural panel includes a closed-cell foam core formed of a metallic material; a first carbon-fiber panel bonded to a first side of the closed-cell foam core; and a second carbon-fiber panel bonded to a second side of the closed-cell foam core such that the foam core is disposed between the first carbon-fiber panel and the second carbon-fiber panel.

Abstract: A first panel defines a first surface characterized by a first base portion and a protuberance extending from the first base portion. A second panel defines a second surface having a second base portion and a depression. The protuberance extends into the depression, and adhesive is disposed on the first base portion, the protuberance, the second base portion, and in the depression, to bond the first panel to the second panel. The protuberance and surface defining the depression provide regions of shear when the base portions are in peel, thereby increasing the strength of the adhesive joint between the first and second panels.

Abstract: A method of joining a first thermoplastic component with a second thermoplastic component includes abutting a joint surface of the first thermoplastic component against a joint surface of the second thermoplastic component. The first thermoplastic component includes a thermoplastic protrusion extending from the joint surface, and the joint surface of the second thermoplastic component defines a receiving pocket adapted to receive the thermoplastic protrusion. Abutting a joint surface of the first thermoplastic component against a joint surface of the second thermoplastic component further includes inserting the thermoplastic protrusion into the receiving pocket. Once abutted, thermal energy is applied to a heat-apply surface of the second thermoplastic component, that is opposite the joint surface. The thermal energy is sufficient to melt a portion of the thermoplastic protrusion and a portion of the joint surface of the second thermoplastic component.

Abstract: A method of integrally forming a composite rib structure includes positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, and the fiber sheet including a plurality of fibers oriented along a first common direction. The method further including extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers are displaced about the protrusion and into each of the respective first channel and second channel; applying a resin within each of respective first channel and second channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold.