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 method of forming a hole in a composite panel includes positioning a first fiber sheet on a layup table, where the layup table has a forming tool extending outward from a portion of the table, and the fiber sheet includes a plurality of fibers oriented along a first common direction. The method further includes extending the forming tool through the first fiber sheet such that a subset of the plurality of fibers are displaced about the forming tool: applying a resin to the sheet of fibers; pre-curing the resin to form a pre-preg part defining a hole about the forming tool; and removing the pre-preg part from the layup table.

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: An assembly includes a fiber-reinforced composite structure, a bushing, and a fastener. The composite structure includes a composite panel on a first side, where the composite panel defines a hemispherical well. The structure further includes a plurality of stiffening ribs on a second side, which are affixed to the composite panel. The composite panel defines a first bore at the center of the hemispherical well, which extends through the structure. The bushing has a hemispherical end and a flat end, and defines a second bore from the center of the hemispherical end to the center of the flat end. The hemispherical end of the bushing is configured to nest within the hemispherical well defined by the composite structure such that the flat end of the bushing is flush with the surrounding composite panel. The fastener is configured to extend within both of the first bore and the second bore.

Abstract: A closure assembly includes a handle assembly having a grab bar. The grab bar is moveable in a normal direction relative to an exterior panel surface of the closure assembly between a retracted position and an extended position. When in the retracted position, an outboard surface of the grab bar is disposed approximately flush with the exterior panel surface. The closure assembly includes a position sensor configured for sensing the presence of an operator, and signals the handle assembly to move the grab bar into the extended position when the presence of the operator is sensed. When the grab bar is grasped, the handle assembly signals a latch mechanism to move into an un-latched position to allow the closure assembly to open.

Abstract: A roof rack system includes first and second longitudinal tracks mountable to the roof substantially parallel to one another. The roof rack system includes first and second roof rack assemblies. Each roof rack assembly has a cross member configured to span between the longitudinal tracks. The roof rack assembly has first and second support modules operatively connecting the cross member to the first and second longitudinal tracks, respectively, such that each of the support modules establishes a four bar linkage with the cross member. The roof rack assembly has a biasing member, as well as a locking mechanism that is configured to hold the support modules in a collapsed position, and is releasable to allow the biasing member to urge the support modules to a deployed position in which the cross member is raised above the longitudinal tracks. The for/aft position of the support modules is adjustable.

Abstract: A seal aligning and retaining assembly includes a seal trough defined by a first side wall, a second side wall and a base. Also included is at least one protrusion integrally formed with the base and extending therefrom, the at least one protrusion having an outer surface. Further included is a seal having at least one aperture including a first elastically deformable inner surface, the seal also having a first elastically deformable outer wall, the seal configured to elastically deform upon disposition of the seal in the seal trough at a first interface between the first elastically deformable inner surface and the outer surface of the at least one protrusion and at a second interface between the first elastically deformable outer wall and at least one of the first side wall and the second side wall.

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: An apparatus for a vehicle having a fluid reservoir fillable with fluid from a container includes a fill tube that empties into the reservoir. A funnel is fixed to the fill tube. The funnel collapses to a stowed position and extends to a use position. The funnel collapses and extends only outside of the fill tube. A cap is connected to the funnel and seals the fill tube opening when the funnel is in the stowed position. The cap is removable from the fill tube opening and has an extension that opens a seal of the container when the funnel is in the use position to permit filling of the reservoir through the funnel and the fill tube.

Abstract: A hood release assembly for a vehicle. The hood release assembly may include a primary hood release and a secondary hood release. The secondary hood release may include a secondary latch including a secondary catch to hold the hood in a partial release position; a secondary release lever pivotally mounted to the secondary latch and including a release handle having an extended position wherein the release handle extends forward past a front edge of the hood and a retracted position; a hood release spring biases the secondary release lever toward the extended position; and a secondary cam lever having a camming surface slidably engaged with the secondary release lever and configured to cause the secondary release lever to be in the retracted position when the hood is in the closed position and in the extended position when the hood is in the partial release position.

Abstract: A roof rack assembly for a vehicle is provided with a first and a second elongated roof rail substantially parallel and spaced from one another. An elongated cross member is secured to the first roof rail and configured to be selectively securable to the second roof rail. The cross member is pivotable between a stowed position and a use position, also referred to as a deployed position. The cross member is substantially parallel with the first roof rail and is not secured to the second roof rail in the stowed position, and not parallel with the first roof rail and secured to the second roof rail in the use position. In the stowed position, the cross member may be within a cavity defined by the roof rail. Two cross members may be used, each being stowable in a different one of the roof rails.

Abstract: A closure assembly includes a handle assembly having a grab bar. The grab bar is moveable in a normal direction relative to an exterior panel surface of the closure assembly between a retracted position and an extended position. When in the retracted position, an outboard surface of the grab bar is disposed approximately flush with the exterior panel surface. The closure assembly includes a position sensor configured for sensing the presence of an operator, and signals the handle assembly to move the grab bar into the extended position when the presence of the operator is sensed. When the grab bar is grasped, the handle assembly signals a latch mechanism to move into an un-latched position to allow the closure assembly to open.

Abstract: A closure assembly includes a panel that defines an opening. A handle includes a grab bar that is moveable from a retracted position through the opening into an extended position. A cover is coupled to and moveable with the handle. The cover is disposed within the opening and flush with the exterior surface of the panel when in a closed position. When the handle moves from the retracted position into the extended position, the cover moves out of the closed position to allow the handle to pass through the opening. When the handle moves from the extended position into the retracted position, the cover moves into the closed position to close the opening. A closeout is coupled to and moveable with the handle. The closeout moves into an exposed position as the handle moves into the extended position to conceal the remainder of the opening not occupied by the handle.

Abstract: A closure assembly includes a panel that defines an opening. A handle includes a grab bar that is moveable from a retracted position through the opening into an extended position. A cover is coupled to and moveable with the handle. The cover is disposed within the opening and flush with the exterior surface of the panel when in a closed position. When the handle moves from the retracted position into the extended position, the cover moves out of the closed position to allow the handle to pass through the opening. When the handle moves from the extended position into the retracted position, the cover moves into the closed position to close the opening. A closeout is coupled to and moveable with the handle. The closeout moves into an exposed position as the handle moves into the extended position to conceal the remainder of the opening not occupied by the handle.

Abstract: A roof rack system includes first and second longitudinal tracks mountable to the roof substantially parallel to one another. The roof rack system includes first and second roof rack assemblies. Each roof rack assembly has a cross member configured to span between the longitudinal tracks. The roof rack assembly has first and second support modules operatively connecting the cross member to the first and second longitudinal tracks, respectively, such that each of the support modules establishes a four bar linkage with the cross member. The roof rack assembly has a biasing member, as well as a locking mechanism that is configured to hold the support modules in a collapsed position, and is releasable to allow the biasing member to urge the support modules to a deployed position in which the cross member is raised above the longitudinal tracks. The for/aft position of the support modules is adjustable.

Abstract: A roof rack assembly includes first and second roof rails spaced from one another, each roof rail having a respective deployable roof rack bow and a respective drive mechanism operatively connected to the roof rack bow that causes the roof rack bow to extend in length by a predetermined amount when pivoted from a stowed position to a deployed position and retract in length by the predetermined amount when pivoted from the deployed position to the retracted position. The predetermined amount that the bows extend when pivoted is sufficient to cause the respective roof rack bows to span from the first roof rail to the second roof rail when in the deployed position.

Abstract: A roof rack assembly includes a first roof rail and a second roof rail spaced a first distance from one another on the vehicle roof. The first roof rail has a first slot extending partially along the length of the first roof rail. A first bow member is connected at a first pivot member to the first roof rail at the first slot. A first linkage member has a first portion connected at a second pivot member to the first bow member and a second portion connected at a third pivot member to the first roof rail. The first linkage member pulls the first pivot member toward the third pivot member so the first bow member translates in the first slot as the first bow member is pivoted away from the first rail.

Abstract: An apparatus for a vehicle having a fluid reservoir fillable with fluid from a container includes a fill tube that empties into the reservoir. A funnel is fixed to the fill tube. The funnel collapses to a stowed position and extends to a use position. The funnel collapses and extends only outside of the fill tube. A cap is connected to the funnel and seals the fill tube opening when the funnel is in the stowed position. The cap is removable from the fill tube opening and has an extension that opens a seal of the container when the funnel is in the use position to permit filling of the reservoir through the funnel and the fill tube.

Abstract: A roof rack assembly includes a first roof rail and a second roof rail spaced a first distance from one another on the vehicle roof. The first roof rail has a first slot extending partially along the length of the first roof rail. A first bow member is connected at a first pivot member to the first roof rail at the first slot. A first linkage member has a first portion connected at a second pivot member to the first bow member and a second portion connected at a third pivot member to the first roof rail. The first linkage member pulls the first pivot member toward the third pivot member so the first bow member translates in the first slot as the first bow member is pivoted away from the first rail.

Abstract: A vehicle adapted to carry elongate cargo includes, but is not limited to, a body having a cargo support surface having a first opening. A first support member is housed within the first opening and is configured to move inwardly and outwardly with respect to the first opening. A first restraining member is connected to the first support member and oriented generally transversely thereto. The first restraining member is configured to move towards and away from the cargo support surface as the first support member moves inwardly and outwardly with respect to the first opening, and to compress the elongate cargo against the cargo support surface. The body is configured to engage the first support member and to inhibit the first support member from moving away from the body. The first restraining member and the cargo support surface cooperate to restrain the elongate cargo.