Abstract: In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Abstract: In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Abstract: An energy absorbing device includes a honeycomb body having two or more tubes stacked transversely with one another along a longitudinal axis. The honeycomb body includes an inboard portion and an outboard portion. The inboard portion of the honeycomb body is arranged along the longitudinal axis and has an inboard portion bending stiffness. The outboard portion of the honeycomb body is arranged outboard of the longitudinal axis, is coupled to the inboard portion of the honeycomb body, and has an outboard portion bending stiffness. The outboard portion bending stiffness of the outboard portion is greater than the inboard portion bending stiffness of the inboard portion. Structural members for vehicle bodies and vehicle bodies are also described.

Abstract: An energy absorbing device includes a composite or metallic component having greater than or equal to three walls forming a component channel with a longitudinal length and a polymeric component. The polymeric component has a honeycomb structure with two or more walls defining honeycomb tubes and supported within the component channel with the honeycomb tubes stacked transversely along the longitudinal length of the component channel. Ends of the honeycomb tubes abut the composite or metal component. The composite or metal component, or the polymeric component, has a bending stiffness greater than a bending stiffness of the honeycomb structure. Rocker assemblies and vehicle bodies are also described.

Abstract: A rail extension, comprising: a base extending from an end of the rail extension, wherein the base includes vehicle rail attachments configured to attach to a vehicle rail; a front member configured for attachment to a bumper beam; a body extending from the base to the front member; wherein the body comprises reinforcing members; wherein the body comprises a first polymeric material; wherein the reinforcing members comprise a second polymeric material.

Abstract: Laminated parts having selective perforations and methods for producing laminated parts using selective perforations are disclosed. Also disclosed are hybrid parts having sequenced plies of unequal dimensions and methods for producing hybrid parts using sequenced plies of unequal dimensions.

Abstract: A device for producing a composite part includes a first platen structure, a second platen structure, a first plate structure, a second plate structure, a first press pad, and a second press pad. The first platen structure, the first plate structure, and the first press pad form a first assembly. The second platen structure, the second plate structure, and the second press pad form a second assembly. A cavity for receiving a laminate is arranged between the first assembly and the second assembly, the cavity including a wall structure arranged to surround the laminate. The wall structure includes an insulating material. A process for the device is also described.

Abstract: A molding process and device produce a hybrid composite part. The process includes configuring a mold cavity (102) to receive a prepreg material (116), configuring the mold cavity further to receive an injection of material, and providing a mold core (104) including at least one main core (112). The at least one main core (112) are configured to move with respect to the mold core (104). The process includes moving the mold core (104) with respect to the mold cavity (102) with a first actuator mechanism, moving the mold core to take a first configuration, forming with the mold core in the first configuration a preform from the prepreg material, moving the mold core to take a second configuration, and over molding onto the preform with the injection of the material with the mold core in the second configuration.

Abstract: A rail extension, comprising: a base extending from an end of the rail extension, wherein the base includes vehicle rail attachments configured to attach to a vehicle rail; a front member configured for attachment to a bumper beam; a body extending from the base to the front member; wherein the body comprises reinforcing members; wherein the body comprises a first polymeric material; wherein the reinforcing members comprise a second polymeric material.

Abstract: A process for constructing a hybrid material part includes mixing a metal powder and a binder to form a compounded mixture, heating the compounded mixture, injecting the compounded mixture into a first mold to form a green part, and debinding the green part to form a brown part. The process further includes sintering the brown part to form a sintered part, and over-molding the sintered part with a plastic in a second mold of an injection molding machine to form the hybrid material part. A hybrid material pump part is disclosed as well.

Abstract: An energy absorber for a vehicle, comprising: a continuous beam to extend across a width of vehicle, the beam defining a plurality of inward facing cavities in a center section, with adjacent inward facing cavities separated from one another by an inward facing rib, and at each end portion a plurality of outward facing cavities, with adjacent outward facing cavities separated from one another by an outward facing rib, wherein the center section includes a panel that is continuous on its outward side, and that forms a relative bottom of each of the plurality of inward facing cavities with its inward face.

Abstract: This disclosure includes armrests having one or more laminates and methods and kits for making the same. Some armrests include an elongated beam extending between a first end and a second end, the elongated beam having one or more laminates configured to be disposed along the elongated beam, each including a plurality of fibers dispersed within a matrix material, and a reinforcing structure having a plurality of ribs, the reinforcing structure configured to be coupled to the one or more laminates, where the first end of the elongated beam is configured to be pivotally coupled to a mount. In some armrests, the one or more laminates are configured to be disposed along the elongated beam such that the one or more laminates define a channel and/or an arch extending between the first and second ends.

Abstract: A rail extension system (16), comprising: a vehicle rail (60); a bumper beam (20); a polymeric rail extension (1) comprising: a base (2) extending from one end of the rail extension having vehicle attachment configured to attach to the vehicle rail (60); a front member 4) configured for attachment to the bumper beam (20); a body (5) extending from the base (2) to the front member (4); an aperture (100) extending from the base (2) to the front member (4); a connection member (102) attached to the bumper beam (20) and extending through the aperture (100) to attach to the vehicle rail (60).

Abstract: A structural body of a vehicle comprises: a hollow component comprising walls that define a channel, wherein the component has a component length, and wherein the component is selected from the group consisting of beam, rail (58), pillar (50,52,54,5), chassis, floor rocker (60), and cross-bar, or combinations comprising at least one of the foregoing; and a plastic-metal hybrid reinforcement (1) having cavities therethrough (14), and a support (6) having greater than or equal to 3 walls forming a support channel. The plastic element (4) is located in the support channel (6) wherein the reinforcement (1) is located in the component channel.

Abstract: An energy absorber for a vehicle, comprising: a continuous beam to extend across a width of vehicle, the beam defining a plurality of inward facing cavities in a center section, with adjacent inward facing cavities separated from one another by an inward facing rib, and at each end portion a plurality of outward facing cavities, with adjacent outward facing cavities separated from one another by an outward facing rib, wherein the center section includes a panel that is continuous on its outward side, and that forms a relative bottom of each of the plurality of inward facing cavities with its inward face.

Abstract: A rail extension system (16), comprising: a vehicle rail (60); a bumper beam (20); a polymeric rail extension (1) comprising: a base (2) extending from one end of the rail extension having vehicle attachment configured to attach to the vehicle rail (60); a front member 4) configured for attachment to the bumper beam (20); a body (5) extending from the base (2) to the front member (4); an aperture (100) extending from the base (2) to the front member (4); a connection member (102) attached to the bumper beam (20) and extending through the aperture (100) to attach to the vehicle rail (60).

Abstract: In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Abstract: In an embodiment, a component for an underrun protection device can comprise: a housing member (10), comprising a main body (100) having a base plate (108) with a top wall (103), bottom wall (109), and optional side walls (104), extending from one side of the base plate (108) to form a housing (115); an arm (101) extending from another side of the base plate (108), wherein the arm (101) comprises a base (109) in contact with the base plate (108), arm sides (105) that extend from the base (109) toward a connection area (107), wherein the arm sides (105) form an arm channel (113); a body polymeric insert (200) comprising body insert ribs (202) and body insert channels (204); and an arm polymeric insert (300) comprising arm insert ribs (302) and arm insert channels (304), wherein the arm polymeric insert (300) is located in the arm channel (113).

Abstract: In an embodiment, a component for an underrun protection device can comprise: a housing member (10), comprising a main body (100) having a base plate (108) with a top wall (103), bottom wall (109), and optional side walls (104), extending from one side of the base plate (108) to form a housing (115); an arm (101) extending from another side of the base plate (108), wherein the arm (101) comprises a base (109) in contact with the base plate (108), arm sides (105) that extend from the base (109) toward a connection area (107), wherein the arm sides (105) form an arm channel (113); a body polymeric insert (200) comprising body insert ribs (202) and body insert channels (204); and an arm polymeric insert (300) comprising arm insert ribs (302) and arm insert channels (304), wherein the arm polymeric insert (300) is located in the arm channel (113).