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: A foamed part, includes: a long glass fiber filled polymeric material, wherein the long glass fibers have an initial length before molding of the foamed part and a final length after molding of the foamed part; wherein a post-molding length of the long glass fibers in the foamed part is greater than or equal to a post-molding length of long glass fibers in a similarly dimensioned foamed part made without a pressurized plasticizing unit.

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: This disclosure includes vehicle cross members and related methods. Some cross members include an elongated beam having a sidewall extending between first and second ends to define a first channel extending along a longitudinal axis of the beam and across at least longitudinally adjacent first and second sections of the beam, the first channel being open on a first side of the beam, and a second channel extending along the longitudinal axis and across at least the second section, the second channel being disposed below the first channel and open on a second side of the beam that is opposite the first side. Some cross members include a composite body having a plastic material and one or more laminates, where the body defines the beam such that at least one of the laminate(s) borders a majority of an inner cross-sectional perimeter of each of the first and second channels.

Abstract: Pedestrian protection device including a composite body (146) having a plastic material (150) and one or more laminates (154), each including fibers (158) dispersed within a matrix material, wherein the body (146) defines an elongated beam (74) extending between first and second ends, the elongated beam (74) having first and second flanges (86), each extending between the first and second ends, and a web (94) extending between and connecting the first and second flanges (86), and wherein at least one of the one or more laminates (154) is disposed along the first flange (86, 90) and/or at least one of the one or more laminates (154) is disposed along the second flange (86, 90). In some devices, an outer surface (126, 130) of the first flange (86, 90) that faces away from the along the second flange (86, 90) is convex. In some devices, the matrix material of at least one of the one or more laminates (154) includes the plastic material (150).

Abstract: In an embodiment, a side door for a vehicle, includes: a structure comprising a shell comprising a shell support beam positioned across a main body portion of the shell, wherein the shell support beam comprises substantially unidirectional fiber strip sections; wherein the shell comprise a inner shell and a outer shell; and wherein the side door has a score of at least 4 points in a side impact test conducted according to European New Car Assessment Protocol (Euro NCAP) Side Impact Testing Protocol Version 5.2 (November 2011).

Abstract: Some of the present vehicle cross members have a composite body including a plastic material and one or more laminates, where the body defines an elongated beam extending between first and second ends and where at least one of the laminate(s) is at least partially disposed along the beam. In some cross members, the laminate(s) at least partially disposed along the beam span a total distance along the beam that is less than 50% of a length of the beam. In some cross members, at least one of the first and second ends of the beam defines one or more openings into the beam for securing the beam to a vehicle. In some cross members, the body defines a first support unitary with and extending from the beam, where at least one of the laminate(s) is at least partially disposed along each of the beam and the first support.

Abstract: A foamed part, includes: a long glass fiber filled polymeric material, wherein the long glass fibers have an initial length before molding of the foamed part and a final length after molding of the foamed part; wherein a post-molding length of the long glass fibers in the foamed part is greater than or equal to a post-molding length of long glass fibers in a similarly dimensioned foamed part made without a pressurized plasticizing unit.

Abstract: In an embodiment, a side door for a vehicle, includes: a structure comprising a shell comprising a shell support beam positioned across a main body portion of the shell, wherein the shell support beam comprises substantially unidirectional fiber strip sections; wherein the shell comprise a inner shell and a outer shell; and wherein the side door has a score of at least 4 points in a side impact test conducted according to European New Car Assessment Protocol (Euro NCAP) Side Impact Testing Protocol Version 5.

Abstract: In an embodiment, a side door for a vehicle, includes: a structure comprising a plastic shell comprising a shell support beam positioned across a main body portion of the shell, wherein the shell support beam comprises substantially unidirectional fiber strip sections; wherein the plastic shell comprise a plastic inner shell and a plastic outer shell; and wherein the side door has a score of at least 4 points in a side impact test conducted according to European New Car Assessment Protocol (Euro NCAP) Side Impact Testing Protocol Version 5.2 (November 2011).

Abstract: In an embodiment, a side door for a vehicle, includes: a structure comprising a plastic shell comprising a shell support beam positioned across a main body portion of the shell, wherein the shell support beam comprises substantially unidirectional fiber strip sections; wherein the plastic shell comprise a plastic inner shell and a plastic outer shell; and wherein the side door has a score of at least 4 points in a side impact test conducted according to European New Car Assessment Protocol (Euro NCAP) Side Impact Testing Protocol Version 5.2 (November 2011).

Abstract: In an embodiment, a side door for a vehicle can comprise: a structure comprising a plastic inner shell comprising a fiber strip, and a plastic outer shell comprising an outer shell support beam positioned across a width of the outer shell. The outer shell support beam can comprise a fiber strip with ?50 wt. % fibers oriented at an angle of less than or equal to ±45° to a main axis. In an embodiment, a method for making the side door for a vehicle can comprise: flow molding a fiber-reinforced polymer over a fiber strip to form a plastic inner shell; flow molding a fiber-reinforced polymer over a fiber strip deposited to form a plastic outer shell, wherein the outer shell comprises an outer shell support beam positioned across a width of the outer shell; and joining the inner shell and the outer shell together to form a composite structure.

Abstract: In an embodiment, a side door for a vehicle can comprise: a structure comprising a plastic inner shell comprising a fiber strip, and a plastic outer shell comprising an outer shell support beam positioned across a width of the outer shell. The outer shell support beam can comprise a fiber strip with ?50 wt. % fibers oriented at an angle of less than or equal to ±45° to a main axis. In an embodiment, a method for making the side door for a vehicle can comprise: flow molding a fiber-reinforced polymer over a fiber strip to form a plastic inner shell; flow molding a fiber-reinforced polymer over a fiber strip deposited to form a plastic outer shell, wherein the outer shell comprises an outer shell support beam positioned across a width of the outer shell; and joining the inner shell and the outer shell together to form a composite structure.