Abstract: A hybrid structure includes a frame member with at least three walls, forming a channel having a convex portion where two walls meet. A concave deformation is present in at least one convex portion, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion. A plastic reinforcement member is present in the channel, wherein a portion of the reinforcement member extends into the opening and on the concave deformation.

Abstract: In an embodiment, a heat dissipating system for a light can include: a light source comprising an LED; a reflector adjacent the LED; a housing around the LED module; and a flexible conductive connector attached at one end to a heat sink and at another end to the light source, and configured to conduct heat away from the light source and to the heat sink. The heat sink is located remote from the light source. In an embodiment, a method of dissipating heat away from a LED module can include: conducting heat from the LED module through a flexible conductive connector to a heat sink, wherein a lamp comprises the LED module, a housing, and a reflector, and wherein the heat sink is located external to the LED housing.

Abstract: A hybrid structure, comprising: a frame member comprising at least three walls forming a channel having a convex portion where two walls meet; a concave deformation in at least one of the convex portions, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion; and a plastic reinforcement member in the channel, wherein a portion of the reinforcement member extends into the opening and on the deformation.

Abstract: An underrun protection device for a vehicle comprises a hybrid beam formed of a preform member and a thermoplastic formed onto the preform member, and configured to attach to a vehicle attachment element, the hybrid beam comprises the preform member defines a channel and is configured to couple with the vehicle and extend along a side of the vehicle parallel with a centerline of the vehicle, with an opening of the channel oriented away from the centerline, wherein the channel is defined by an inside surface at least partially facing away from the centerline, and an outside surface at least partially facing the centerline; and a thermoplastic beam formed of the thermoplastic and shaped to conform to the channel of the preform member, the thermoplastic beam at least partially abutting the inside surface of the channel.

Abstract: Disclosed herein are methods for manufacturing a functionally graded polymer material. A method comprises preparing a melted polymer mixture comprising a thermoplastic polymer and a magnetic filler; molding the melted polymer mixture; and applying a magnetic field to a portion of the melted polymer mixture to form the functionally graded article, wherein as the melted polymer mixture flows into the mold, the melted polymer mixture comes into contact with the magnet field. Another method comprises molding the melted polymer mixture; and applying a magnetic field from a first magnet to a first portion of the melted polymer mixture and applying a magnetic field from a second magnet to a second portion of the melted polymer mixture to form the functionally graded article, wherein the first magnet and the second magnet are positioned in a manner such that the magnetic field produced by each are nonoverlapping.

Abstract: Disclosed herein are methods for manufacturing a functionally graded polymer material. The methods comprise preparing a melted polymer mixture comprising a thermoplastic polymer and a magnetic filler dispersed in the thermoplastic polymer, molding the melted polymer mixture and applying a magnetic field to a portion of the melted polymer mixture to form a functionally graded polymer material. The resulting functionally graded polymer material has a magnetic filler gradient formed through a thickness of the material.

Abstract: An underrun protection device for a vehicle comprises a hybrid beam formed of a preform member and a thermoplastic formed onto the preform member, and configured to attach to a vehicle attachment element, the hybrid beam comprises the preform member defines a channel and is configured to couple with the vehicle and extend along a side of the vehicle parallel with a centerline of the vehicle, with an opening of the channel oriented away from the centerline, wherein the channel is defined by an inside surface at least partially facing away from the centerline, and an outside surface at least partially facing the centerline; and a thermoplastic beam formed of the thermoplastic and shaped to conform to the channel of the preform member, the thermoplastic beam at least partially abutting the inside surface of the channel.

Abstract: In some embodiments, a headlamp assembly can comprise: a reflector, a mounting bracket, a housing, and a light source. The reflector can have a lip at a light source opening and a peripheral rim with a reflector portion extending from the lip to a peripheral rim. The mounting bracket can be configured to attach to the reflector. The mounting bracket can comprise attachment structures configured to mate with the lip, and adjustment features that enable horizontal, vertical, and pivotal adjustment. The light source can extend into the reflector through the light source opening.

Abstract: In one embodiment, an electric vehicle charging station comprises a body attached to a base, wherein the base is operably connected to a deflector mechanism, wherein the body moves from a rest position disposed along a major axis of the electric vehicle charging station to an impact position, with an articulation angle disposed therebetween, upon an impact having a force greater than or equal to 5 kiloNewtons.

Abstract: A stand for holding a device comprising: a base; a first support member oriented in a vertical direction in operable communication with the base; a second support member oriented in a horizontal direction in operable communication with the first support member; wherein the second support member comprises at least one retaining member angled away from the second support member in a vertical direction; wherein at least one of the base, first support member, and second support member comprises an adjustment mechanism allowing for the adjustment of the location of the retaining member; wherein the stand comprises a one-piece unit.

Abstract: In an embodiment, heat sink system can comprise: an integrally formed plastic heat sink and a printed circuit board package, wherein the plastic heat sink comprises a thermally conductive plastic having a thermal conductivity of at least 1.0 W/mK. In another embodiment, hybrid heat sink system, comprising: an integrally formed plastic heat sink and an insert, wherein the plastic heat sink comprises a thermally conductive plastic, the plastic heat sink and the insert each having a cylindrical shape, and wherein the insert comprises a feature of lancing provisions, corrugations, embossing, holes, or a combination comprising at least one of the foregoing features.

Abstract: In an embodiment, a power inverter casing, comprises: a body having a first component removably attached to a second component, wherein, when joined, a recess is formed therebetween; a member removably attached to the first component and the second component opposite the recess; and a handle located in the recess and removably attached to the first component and the second component; wherein the member contains a first member illuminating element, and/or the recess contains a recess illuminating element, and/or the handle contains a handle illuminating element.

Abstract: In an embodiment, an energy absorbing assembly comprises a foam stage having a first surface and a second surface, wherein the second surface comprises a recess; and a thermoplastic stage comprising a frame and crush lobes; wherein the crush lobes extend from the frame of the thermoplastic stage into the recess. In another embodiment, a method of making an energy absorbing assembly comprises forming a foam stage having a first surface and a second surface, wherein the second surface comprises recesses; forming a thermoplastic stage having a frame and crush lobes protruding from the frame; and engaging the recesses and the crush lobes to form the energy absorbing assembly.

Abstract: A road barrier energy absorber system, comprising: an energy absorber unit comprising outer walls with a stiffening element located between the outer walls; wherein the energy absorber unit has a size and shape to be located on at least one side of a road barrier; and wherein upon an impact, the energy absorber unit will absorb, e.g., up to 300 kJ of energy.

Abstract: Disclosed herein are methods for manufacturing a functionally graded polymer material. The methods comprise preparing a melted polymer mixture comprising a thermoplastic polymer and a magnetic filler dispersed in the thermoplastic polymer, molding the melted polymer mixture and applying a magnetic field to a portion of the melted polymer mixture to form a functionally graded polymer material. The resulting functionally graded polymer material has a magnetic filler gradient formed through a thickness of the material.

Abstract: In an embodiment, a power inverter casing, comprises: a body having a first component removably attached to a second component, wherein, when joined, a recess is formed therebetween; a member removably attached to the first component and the second component opposite the recess; and a handle located in the recess and removably attached to the first component and the second component; wherein the member contains a first member illuminating element, and/or the recess contains a recess illuminating element, and/or the handle contains a handle illuminating element.

Abstract: In an embodiment, a heat dissipating system for a light can include: a light source comprising an LED; a reflector adjacent the LED; a housing around the LED module; and a flexible conductive connector attached at one end to a heat sink and at another end to the light source, and configured to conduct heat away from the light source and to the heat sink. The heat sink is located remote from the light source. In an embodiment, a method of dissipating heat away from a LED module can include: conducting heat from the LED module through a flexible conductive connector to a heat sink, wherein a lamp comprises the LED module, a housing, and a reflector, and wherein the heat sink is located external to the LED housing.

Abstract: In one embodiment, an electric vehicle charging station comprises a body attached to a base, wherein the base is operably connected to a deflector mechanism, wherein the body moves from a rest position disposed along a major axis of the electric vehicle charging station to an impact position, with an articulation angle disposed therebetween, upon an impact having a force greater than or equal to 5 kiloNewtons.

Abstract: In one embodiment, an electric vehicle charging station comprises a base and a body extending from the base along a major axis of the electric vehicle charging station; and an energy absorbing system comprising a first wall, a second wall, and a connecting wall disposed therebetween the first wall and the second wall creating a compartment; wherein the body receives the energy absorbing system; and wherein the energy absorbing system is configured to engage an impacting object.