Abstract: Compression molding methods for improving the durability and weatherability of a composite material are provided. The methods include disposing a protective surface film on a composite material; adhering the protective surface film to the composite material; and compression molding the protective surface film. The composite material comprises a thermoplastic polymer and a reinforcement material. The protective surface film comprises at least one stabilizer that minimizes or prevents degradation of the underlying composite material when exposed to ultraviolet radiation and/or heat. The composite material may be heated in an oven having an environment comprising oxygen. The protective surface film may be disposed on the composite material prior to the composite material entering the oven; while the composite material is in the oven; or after the composite material exits the oven.

Abstract: One variation includes a method including using a reversible dry adhesive system to reversibly couple a first substrate to a second substrate. One variation includes a method including using a reversible dry adhesive system to reversibly couple a first substrate to a second substrate during building or reconfiguring a product.

Abstract: Methods of repairing a defect in a polymeric composite structure are provided. The methods include disposing a patch over a defect in a polymeric composite structure; disposing a textured sheet over the polymeric patch, applying pressure to the polymeric patch and the textured sheet; and heating the polymeric patch. The textured sheet has a surface texture that is a negative of a surface texture of the polymeric composite structure.

Abstract: In an example of a method disclosed herein, a polycarbonate with a hydrophilic surface is formed. An ether substituted dichlorosilane, phosgene, and a Bisphenol reactant are polymerized to form a polycarbonate including a hydrolyzable silane in its backbone chain. The hydrolyzable silane includes an alkoxy group attached to a silicon atom. The alkoxy group on the hydrolyzable silane is converted to a more hydrophilic functional group to form the polycarbonate with the hydrophilic surface.

Abstract: A wheel impact sensing system of a vehicle includes at least one sensor measuring an acceleration of a vehicle wheel resulting from an impact to the vehicle wheel. A processor determines a severity of the impact to the vehicle wheel as function of the acceleration measurement. An output device alerts a driver to potential damage of the vehicle wheel based on the determined impact severity to the vehicle wheel.

Abstract: In an example of a method disclosed herein, a polycarbonate with a hydrophilic surface is formed. An ether substituted dichlorosilane, phosgene, and a Bisphenol reactant are polymerized to form a polycarbonate including a hydrolyzable silane in its backbone chain. The hydrolyzable silane includes an alkoxy group attached to a silicon atom. The alkoxy group on the hydrolyzable silane is converted to a more hydrophilic functional group to form the polycarbonate with the hydrophilic surface.

Abstract: Sheet metal workpieces are preheated to a temperature in the range of about 100° C. to about 500° C. for warm forming between press-actuated forming dies. The forming dies are not heated, but are coated with a liquid lubricating material suitable for the forming of the preheated sheet metal workpiece. For example, the liquid lubricating material is suitably a halogenated hydrocarbon that will adhere to unheated die surfaces and serve in the forming of the sheet metal workpiece into a vehicle body panel or other product. But the liquid lubricating material is composed so as to evaporate from surfaces of the formed workpiece at a temperature below about 200° C., so that the workpiece does not have to be cleaned before it is decoratively finished. The lubricant material may be vaporized, for example, into a warm stream of air or nitrogen and carried to a recovery or disposal system.

Abstract: A lightweight spare tire system. The lightweight spare tire system includes a carbon fiber composite vehicle rim that is suitable for use with a spare tire and a lightweight tire that is suitable for use with the carbon fiber composite rim. The lightweight tire and rim creates a lightweight spare wheel that may be used on a vehicle.

Abstract: A method of mitigating galvanic corrosion on a vehicle is provided for use of metals with carbon containing composites. An electrically conductive material comprising a plurality of electrically conductive metallic particles and a polymer is applied to a corrosion susceptible region of an assembly having a carbon-reinforced composite and a metal. The electrically conductive material has an electrical conductivity of greater than or equal to about 1×10?4 S/m and serves as a sacrificial anode to mitigate or prevent corrosion of the metal in the assembly. Also provided are assemblies for a vehicle having reduced galvanic corrosion that include a metal component in contact with a carbon-reinforced composite, which defines a corrosion susceptible region having an electrically conductive material disposed therein.

Abstract: Sheet metal workpieces are preheated to a temperature in the range of about 100° C. to about 500° C. for warm forming between press-actuated forming dies. The forming dies are not heated, but are coated with a liquid lubricating material suitable for the forming of the preheated sheet metal workpiece. For example, the liquid lubricating material is suitably a halogenated hydrocarbon that will adhere to unheated die surfaces and serve in the forming of the sheet metal workpiece into a vehicle body panel or other product. But the liquid lubricating material is composed so as to evaporate from surfaces of the formed workpiece at a temperature below about 200° C., so that the workpiece does not have to be cleaned before it is decoratively finished. The lubricant material may be vaporized, for example, into a warm stream of air or nitrogen and carried to a recovery or disposal system.

Abstract: A lightweight spare tire system. The lightweight spare tire system includes a carbon fiber composite vehicle rim that is suitable for use with a spare tire and a lightweight tire that is suitable for use with the carbon fiber composite rim. The lightweight tire and rim creates a lightweight spare wheel that may be used on a vehicle.

Abstract: One variation includes a method including using a reversible dry adhesive system to reversibly couple a first substrate to a second substrate. One variation includes a method including using a reversible dry adhesive system to reversibly couple a first substrate to a second substrate during building or reconfiguring a product.

Abstract: A method of mitigating galvanic corrosion on a vehicle is provided for use of metals with carbon containing composites. An electrically conductive material comprising a plurality of electrically conductive metallic particles and a polymer is applied to a corrosion susceptible region of an assembly having a carbon-reinforced composite and a metal. The electrically conductive material has an electrical conductivity of greater than or equal to about 1×10?4 S/m and serves as a sacrificial anode to mitigate or prevent corrosion of the metal in the assembly. Also provided are assemblies for a vehicle having reduced galvanic corrosion that include a metal component in contact with a carbon-reinforced composite, which defines a corrosion susceptible region having an electrically conductive material disposed therein.

Abstract: One embodiment includes a rechargeable charge storage device including a microcapsule disposed within said rechargeable charge storage device; and a thermal retardant chemical species contained within said microcapsule, wherein said microcapsule is adapted to release said chemical species upon being exposed to a triggering event either prior to or during an unstable rise in temperature of said charge storage device.

Abstract: One exemplary embodiment includes a method comprising providing a tire having a component constructed and arranged to cause at least one portion of the tire to have a first stiffness or resistance to force exerted thereon under a first condition and a second stiffness or resistance to force exerted thereon under a second condition and selectively causing the first or second condition to occur.

Abstract: A tire includes a pair of sidewalls in spaced apart relation and extending substantially radially from a respective inner circumferential portion to a respective outer circumferential portion, a tread extending between and connecting outer circumferential portions of the sidewalls, at least a portion of a tire cavity defined by the tread and sidewalls, and a bead portion on the inner circumferential portion of each radially extending sidewall, the bead portion providing an engagement surface for engaging a wheel on which the tire is to be mounted, and a noise reducing foam disposed in at least a portion of the tire cavity.

Abstract: A method of forming an adhesive bond between a first substrate and a second substrate includes applying a semi-crystalline polymeric adhesive composition to a bonding area of the first substrate, and, after applying, disposing the second substrate adjacent to and in contact with the composition to form a workpiece. After disposing, the method includes heating the workpiece to cure the composition and thereby form a crosslinked polymeric adhesive material. After heating, the method includes cooling the workpiece such that the material has a crystalline molecular structure. Concurrent to cooling, the method includes imposing a stress on the material to thereby orient the crystalline molecular structure in a desired direction, and, after imposing, dissipating the stress along the crystalline molecular structure in the desired direction to thereby form the adhesive bond between the first substrate and the second substrate.

Abstract: A method and system for forming a part from a workpiece including a hollow portion, using a mandrel and a conventional press such as a stamping press includes filling the hollow portion of the workpiece with a mandrel material and transforming the mandrel material to form a mandrel. The mandrel material is removable from the formed part and may be recycled to form a mandrel for another workpiece.

Abstract: One embodiment includes compositions of shape memory epoxy polymers.

Abstract: One embodiment includes a rechargeable charge storage device including a microcapsule disposed within said rechargeable charge storage device; and a thermal retardant chemical species contained within said microcapsule, wherein said microcapsule is adapted to release said chemical species upon being exposed to a triggering event either prior to or during an unstable rise in temperature of said charge storage device.