Abstract: The invention relates to a hybrid tailgate for a vehicle, comprising a thermoplastic inner structure forming the carrier frame of the tailgate, and at least one composite reinforcement part to reinforce the carrier frame, wherein the composite reinforcement part is connected to the thermoplastic inner structure at a first surface, wherein the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate. Furthermore, the invention relates to a vehicle comprising such a hybrid tailgate. Moreover, the invention relates to a method of manufacturing such a hybrid tailgate, the method comprising forming a composite laminate part into an insert; placing the insert in an injection molding tool; and over-molding the insert with polymer resin.

Abstract: The invention relates to a hybrid tailgate for a vehicle, comprising a thermoplastic inner structure forming the carrier frame of the tailgate, and at least one composite reinforcement part to reinforce the carrier frame, wherein the composite reinforcement part is connected to the thermoplastic inner structure at a first surface, wherein the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate. Furthermore, the invention relates to a vehicle comprising such a hybrid tailgate. Moreover, the invention relates to a method of manufacturing such a hybrid tailgate, the method comprising forming a composite laminate part into an insert; placing the insert in an injection molding tool; and over-molding the insert with polymer resin.

Abstract: Roof frames and methods of making the same are disclosed. Roof frames may comprise at least a first, second, third, and fourth structures. One or more of the structures may comprise a first surface formed from a first continuous fiber composite comprising a multidirectional laminate. At least one of the first, second, third, and fourth structures may comprise a second surface formed from a second continuous fiber composite comprising a unidirectional laminate, wherein the first surface and the second surface are selected to be formed from the first continuous fiber composite and the second continuous fiber composite, respectively, based at least upon a stress analysis for the respective surface, wherein the first surface exhibits a higher stress profile as compared to the second surface.

Abstract: Fire-retardant composites, methods of making fire-retardant composites, and use thereof are described. A fire-retardant composite can include at least two fire-retardant laminates, and a porous thermoplastic core material disposed between the at least two fire-retardant laminates. Each laminate can have one or more ply, each of the plies can include a plurality of fibers in a thermoplastic polymer matrix that includes a fire-retardant composition. The fire-retardant composite meets European fire-retardant standards for rail transportation.

Abstract: Roof frames and methods of making the same are disclosed. Roof frames may comprise at least a first, second, third, and fourth structures. One or more of the structures may comprise a first surface formed from a first continuous fiber composite comprising a multidirectional laminate. At least one of the first, second, third, and fourth structures may comprise a second surface formed from a second continuous fiber composite comprising a unidirectional laminate, wherein the first surface and the second surface are selected to be formed from the first continuous fiber composite and the second continuous fiber composite, respectively, based at least upon a stress analysis for the respective surface, wherein the first surface exhibits a higher stress profile as compared to the second surface.

Abstract: The invention relates to a hybrid tailgate for a vehicle, comprising a thermoplastic inner structure forming the carrier frame of the tailgate, and at least one composite reinforcement part to reinforce the carrier frame, wherein the composite reinforcement part is connected to the thermoplastic inner structure at a first surface, wherein the composite reinforcement part forms a continuous load path in the inner structure enclosing a tailgate window opening for a window glazing part of the tailgate. Furthermore, the invention relates to a vehicle comprising such a hybrid tailgate. Moreover, the invention relates to a method of manufacturing such a hybrid tailgate, the method comprising forming a composite laminate part into an insert; placing the insert in an injection molding tool; and over-molding the insert with polymer resin.

Abstract: Fire-retardant composites, methods of making fire-retardant composites, and use thereof are described. A fire-retardant composite can include at least two fire-retardant laminates, and a porous thermoplastic core material disposed between the at least two fire-retardant laminates. Each laminate can have one or more ply, each of the plies can include a plurality of fibers in a thermoplastic polymer matrix that includes a fire-retardant composition. The fire-retardant composite meets European fire-retardant standards for rail transportation.

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: 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 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 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: In an embodiment, a road barrier energy absorption unit can comprise: a vehicle crush section configured to absorb impact energy when impacted with greater than or equal to 5 kN force; a post channel configured to receive a road barrier post; and a guardrail attachment. The energy absorption unit can be disposed over the post and a guardrail can attach to the energy absorption unit. In an embodiment, a road barrier energy absorber system comprises: posts; road barrier energy absorption unit; and a guardrail extending between the energy absorber units. Each post is disposed in one of the energy absorber units. The energy absorber units comprise a vehicle crush section configured to absorb impact energy when impacted with greater than or equal to 5 kN force. In an embodiment, a guardrail can comprise: an outer wall and stiffening elements, wherein the guardrail comprises a plastic.

Abstract: In an embodiment, a road barrier energy absorption unit can comprise: a vehicle crush section configured to absorb impact energy when impacted with greater than or equal to 5 kN force; a post channel configured to receive a road barrier post; and a guardrail attachment. The energy absorption unit can be disposed over the post and a guardrail can attach to the energy absorption unit. In an embodiment, a road barrier energy absorber system comprises: posts; road barrier energy absorption unit; and a guardrail extending between the energy absorber units. Each post is disposed in one of the energy absorber units. The energy absorber units comprise a vehicle crush section configured to absorb impact energy when impacted with greater than or equal to 5 kN force. In an embodiment, a guardrail can comprise: an outer wall and stiffening elements, wherein the guardrail comprises a plastic.

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.