Abstract: A fairing configured to be positioned on a roof of a vehicle. The fairing has a forward end and a rearward end. The fairing comprises a flow controlling outer body defining a central forward opening. The fairing includes at least one actuatable panel movably coupled to the flow controlling outer body and a central body aligned with the central forward opening of the flow controlling outer body. At least one air channel open to the central forward opening that extends between the at least one actuatable panel and the central body. The fairing includes at least one actuator configured to move the at least one actuatable panel through a plurality of positions to direct an air flow along at least one of 1) the at least one air channel and 2) an outboard side of the at least one actuatable panel.

Abstract: A fairing configured to be positioned on a roof of a vehicle. The fairing has a forward end and a rearward end. The fairing comprises a flow controlling outer body defining a central forward opening. The fairing includes at least one actuatable panel movably coupled to the flow controlling outer body and a central body aligned with the central forward opening of the flow controlling outer body. At least one air channel open to the central forward opening that extends between the at least one actuatable panel and the central body. The fairing includes at least one actuator configured to move the at least one actuatable panel through a plurality of positions to direct an air flow along at least one of 1) the at least one air channel and 2) an outboard side of the at least one actuatable panel.

Abstract: Disclosed is a roof fairing for a vehicle, such as a truck hauling a trailer. The roof fairing includes a body defining a flow directing exterior surface. The body including at least one flow directing channel that is sunk into the body toward an inner space defined by an interior surface of the body. The flow directing channel comprises a venturi construction terminating at the trailing edge. The venturi construction is configured to direct flow toward an exterior surface of the trailer when coupled to the truck.

Abstract: Disclosed is a roof fairing for a vehicle, such as a truck hauling a trailer. The roof fairing includes a body defining a flow directing exterior surface. The body including at least one flow directing channel that is sunk into the body toward an inner space defined by an interior surface of the body. The flow directing channel comprises a venturi construction terminating at the trailing edge. The venturi construction is configured to direct flow toward an exterior surface of the trailer when coupled to the truck.

Abstract: In one embodiment, a vehicle energy absorber system, comprises: blow molded crush lobes that are open on one side, wherein the energy absorber comprises fillets having a fillet radius of less than 20 mm and a thickness of less than or equal to 1.5 mm; a bumper beam adjacent the open side; and a fascia, wherein the energy absorber is located between the fascia and the bumper beam. In one embodiment, a method for making a blow molded energy absorber comprises: introducing a molten plastic to a first mold cavity; introducing gas into the plastic to conform the plastic to the interior of the first mold cavity and form a first preform; and separating the first preform along a centerline thereof to form open, first preform portions having first crush lobes.

Abstract: In one embodiment, a vehicle energy absorber system, comprises: blow molded crush lobes that are open on one side, wherein the energy absorber comprises fillets having a fillet radius of less than 20 mm and a thickness of less than or equal to 1.5 mm; a bumper beam adjacent the open side; and a fascia, wherein the energy absorber is located between the fascia and the bumper beam. In one embodiment, a method for making a blow molded energy absorber comprises: introducing a molten plastic to a first mold cavity; introducing gas into the plastic to conform the plastic to the interior of the first mold cavity and form a first preform; and separating the first preform along a centerline thereof to form open, first preform portions having first crush lobes.

Abstract: In one embodiment, a multi-stage energy absorbing system can comprise: a base; and an energy absorber comprising elements, wherein the energy absorber elements comprise a pair of outer sidewalls having a narrow section with a narrow section angle and a wide section with a wide section angle, wherein the narrow section and the wide section are connected by a diverging section with a diverging section angle, wherein the diverging section angle is less than 90°; a connecting wall between the outer sidewalls; a pair of inner sidewalls; and an inner connecting wall, wherein the energy absorbing elements are in a nested arrangement creating an open area between adjacent sidewalls and adjacent connecting walls.

Abstract: In one embodiment, a thermoplastic lower-leg device, comprises: corrugations in a direction perpendicular to an impact direction; and an interior section extending in the impact direction and having an outbound portion having an outbound length D1 extending at an angle, ?1, from the interior section and an inbound portion having an inbound length, D2, extending in a direction opposite the outbound portion at an angle, ?2, from the interior section.

Abstract: In one embodiment, a vehicle energy absorber system, comprises: blow molded crush lobes that are open on one side, wherein the energy absorber comprises fillets having a fillet radius of less than 20 mm and a thickness of less than or equal to 1.5 mm; a bumper beam adjacent the open side; and a fascia, wherein the energy absorber is located between the fascia and the bumper beam. In one embodiment, a method for making a blow molded energy absorber comprises: introducing a molten plastic to a first mold cavity; introducing gas into the plastic to conform the plastic to the interior of the first mold cavity and form a first preform; and separating the first preform along a centerline thereof to form open, first preform portions having first crush lobes.

Abstract: In various embodiments, a structural body of a vehicle comprises: a hollow metal component comprising walls that define a channel, wherein the metal vehicle component has a metal component length, and wherein the metal vehicle component is selected from the group consisting of beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and a plastic reinforcement having a honeycomb structure, wherein the plastic reinforcement is located in the channel. The metal component can be a portion of the structural body of the vehicle.

Abstract: In one embodiment, a thermoplastic lower-leg device, comprises: corrugations in a direction perpendicular to an impact direction; and an interior section extending in the impact direction and having an outbound portion having an outbound length D1 extending at an angle, ?1, from the interior section and an inbound portion having an inbound length, D2, extending in a direction opposite the outbound portion at an angle, ?2, from the interior section.

Abstract: In one embodiment, a vehicle energy absorber system, comprises: blow molded crush lobes that are open on one side, wherein the energy absorber comprises fillets having a fillet radius of less than 20 mm and a thickness of less than or equal to 1.5 mm; a bumper beam adjacent the open side; and a fascia, wherein the energy absorber is located between the fascia and the bumper beam. In one embodiment, a method for making a blow molded energy absorber comprises: introducing a molten plastic to a first mold cavity; introducing gas into the plastic to conform the plastic to the interior of the first mold cavity and form a first preform; and separating the first preform along a centerline thereof to form open, first preform portions having first crush lobes.

Abstract: In various embodiments, a structural body of a vehicle comprises: a hollow metal component comprising walls that define a channel, wherein the metal vehicle component has a metal component length, and wherein the metal vehicle component is selected from the group consisting of beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and a plastic reinforcement having a honeycomb structure, wherein the plastic reinforcement is located in the channel. The metal component can be a portion of the structural body of the vehicle.