Abstract: This disclosure relates to a roof rail for a motor vehicle. In particular, the roof rail includes a divider wall configured to resist a clamping force, such as that which is expected to be applied to the roof rail from a cross bar of a roof rack. An example assembly includes a roof rail with a closed cross-sectional area and an open cross-sectional area separated by a divider wall.

Abstract: A method including generating a plurality of synthetic images of a material, where each synthetic image from among the plurality of synthetic images is associated with a feasibility value greater than a threshold synthetic feasibility value. The method includes determining, for each synthetic image from among the plurality of synthetic images, one or more material properties of the material and one or more process parameters of the material based on the synthetic image and generating a plurality of data points and a pareto surface based on the one or more material properties and the one or more process parameters. The method includes selecting a target data point based on the plurality of data points and a distance between a set of data points from among the plurality of data points and the pareto surface.

Abstract: An assembly for compression molding includes an insert housing defining a plurality of apertures having stop surfaces. The assembly includes a plurality of inserts disposed within the apertures and in engagement with the stop surfaces. The assembly further includes a plurality of gas springs in biased engagement with the inserts. Individual gas springs of the plurality of gas springs are adapted to independently compress under load to permit independent movement of individual inserts within the apertures relative to the insert housing.

Abstract: This disclosure relates to a roof rail for a motor vehicle. In particular, the roof rail includes a divider wall configured to resist a clamping force, such as that which is expected to be applied to the roof rail from a cross bar of a roof rack. An example assembly includes a roof rail with a closed cross-sectional area and an open cross-sectional area separated by a divider wall.

Abstract: A method of forming carbon fibers having internal cavities. The method includes applying a polymer material to a tooling component to form carbon fiber precursor hollow tubes, oxidizing the carbon fiber precursor hollow tubes, and carbonizing the carbon fiber hollow tubes to form carbon fibers, each having a hollow inner cavity.

Abstract: An air extraction system for a motor vehicle includes a trim panel inlet, an air extractor and an acoustic air duct extending from the trim panel inlet to the air extractor. The acoustic air duct includes an outer wall defining an elongated internal airflow passageway and a plurality of channels. Those channels extend along the airflow passageway within the outer wall. At least one of the channels has an expansion chamber.

Abstract: A vehicle structural or semi-structural component assembly or crash sensor assembly includes a body, wherein a first portion of the body comprises a polymer composite material and a sensor mount portion of the body is connected to the first portion; and a sensor directly attached to the sensor mount portion. The sensor mount portion comprises a polymer composite material and a flexible reinforcement material over-molded within the polymer composite material. A method for enabling tunable deceleration characteristics in a vehicle structural or semi-structural component assembly includes forming a structural or semi-structural component for a vehicle from a polymer composite material; over-molding a flexible reinforcement material within the polymer composite material at one or more locations along the component; and attaching a sensor directly to at least one of the one or more locations.

Abstract: A composite vehicle component. The composite vehicle component includes a polymer matrix and carbon spheres dispersed throughout the polymer matrix. The carbon spheres have a diameter of 10 to 400 ?m and include at least 90 wt. % carbon.

Abstract: An assembly for compression molding includes an insert housing defining a plurality of apertures having stop surfaces. The assembly includes a plurality of inserts disposed within the apertures and in engagement with the stop surfaces. The assembly further includes a plurality of gas springs in biased engagement with the inserts. Individual gas springs of the plurality of gas springs are adapted to independently compress under load to permit independent movement of individual inserts within the apertures relative to the insert housing.

Abstract: Carbon particles are disclosed, as well as methods and systems for forming the particles. In one embodiment, the system may include a receiving vessel configured to receive a liquid carbon precursor and at least one orifice at a bottom of the receiving vessel and configured to release droplets of the precursor. A cooling vessel may be positioned below the receiving vessel to receive the droplets and configured to hold a coolant for solidifying the droplets into carbon precursor particles. The method may include introducing a liquid carbon precursor into a tank having a plurality of orifices defined therein such that droplets of the precursor are released from the orifices and solidifying the droplets in a cooling vessel positioned to receive the droplets from the orifices. The method may then include carbonizing the solidified droplets to form carbon particles. The particles may be solid or hollow.

Abstract: An air extraction system includes an air inlet, an air extractor in an acoustic air duct extending from the air inlet to the air extractor. The acoustic air duct includes an outer wall defining an elongated airflow passageway and a plurality of channels extending along and dividing the airflow passageway within the outer wall. A first channel of the plurality of channels includes alternating expansion chambers and constriction zones.

Abstract: An air extraction system includes an air inlet, an air extractor in an acoustic air duct extending from the air inlet to the air extractor. The acoustic air duct includes an outer wall defining an elongated area flow passageway and a plurality of channels extending along and dividing the airflow passageway within the outer wall.

Abstract: An air extraction system for a motor vehicle includes a trim panel inlet, an air extractor and an acoustic air duct extending from the trim panel inlet to the air extractor. The acoustic air duct includes an outer wall defining an elongated internal airflow passageway and a plurality of channels. Those channels extend along the airflow passageway within the outer wall. At least one of the channels has an expansion chamber.

Abstract: In at least one embodiment, a molding method for producing a molded article is provided. The method may include introducing polymer and fiber separately into an extruder in a first ratio to produce a first extruded material having a first fiber content and in a second ratio to produce a second extruded material having a second fiber content different from the first fiber content. The method may further include filling a first region of a mold with the first extruded material and a second region of the mold with the second extruded material. The extruded material may be formed as blanks for use in compression molding or may be introduced into an injection chamber for use in injection molding. The method may be used to form molded articles having a plurality of regions having different fiber contents.

Abstract: A method of forming carbon fibers having internal cavities.

Abstract: Carbon particles are disclosed, as well as methods and systems for forming the particles. In one embodiment, the system may include a receiving vessel configured to receive a liquid carbon precursor and at least one orifice at a bottom of the receiving vessel and configured to release droplets of the precursor. A cooling vessel may be positioned below the receiving vessel to receive the droplets and configured to hold a coolant for solidifying the droplets into carbon precursor particles. The method may include introducing a liquid carbon precursor into a tank having a plurality of orifices defined therein such that droplets of the precursor are released from the orifices and solidifying the droplets in a cooling vessel positioned to receive the droplets from the orifices. The method may then include carbonizing the solidified droplets to form carbon particles. The particles may be solid or hollow.

Abstract: In at least one embodiment, a molding method for producing a molded article is provided. The method may include introducing polymer and fiber separately into an extruder in a first ratio to produce a first extruded material having a first fiber content and in a second ratio to produce a second extruded material having a second fiber content different from the first fiber content. The method may further include filling a first region of a mold with the first extruded material and a second region of the mold with the second extruded material. The extruded material may be formed as blanks for use in compression molding or may be introduced into an injection chamber for use in injection molding. The method may be used to form molded articles having a plurality of regions having different fiber contents.

Abstract: A vehicle tailgate includes a frame, pair of hinges, inner tailgate panel, and outer tailgate panel. The frame has a first outer side-member and a second outer side-member. Each of the outer side-members is secured to ends of a lower outer cross-member. The outer side-members each have an internal surface and an external surface. The internal surfaces define T-slots. One of the pair of hinges is secured to each external surface of the outer side-members. The inner and outer tailgate panels are secured to opposing outer sides of the frame such that the external surfaces of the outer side-members remain exposed.

Abstract: The present disclosure includes atmospheric plasma systems and methods for plasma treating a surface. The plasma system may include a plasma probe configured to receive a source air that is at or above atmospheric pressure and discharge a plasma from a probe tip. It may also include an air supply system including an air supply conduit configured to supply the source air to the plasma probe and a heat source configured to increase a temperature of the source air in the air supply system to above an ambient temperature. The heat source may include an inline heater disposed within the air supply conduit. The source air may be heated to a temperature of 25° C. to 1,000° C. The heated air plasma system may provide a higher plasma dosage to a treated surface and may allow for reduced cycle times and larger plasma treatment working windows.

Abstract: A vehicle body assembly includes an outer component defining a cavity. The outer component has a pair of first flanges. An inner component has a pair of second flanges each joined to one of the first flanges. A reinforcement formed of carbon fiber is disposed in the cavity between the components. The reinforcement includes a faceplate joined to the outer component with a rivet and third flanges each joined to the inner component with a rivet.