A method for manufacturing a motor vehicle air flap apparatus for quantitatively controlling a cooling air flow in a vehicle space, the air flap apparatus encompassing: an apparatus frame having a passthrough opening; at least one air flap that extends along a flap axis and is mounted on the apparatus frame pivotably, around a pivot axis parallel to the flap axis or coaxial therewith, between two operational positions providing different coverage of the passthrough opening; such that the method for manufacturing at least some of the components of the motor vehicle air flap apparatus encompasses an injection-molding method; the method encompasses, for the manufacture of at least two components of the motor vehicle air flap apparatus which are connected to one another by positive engagement, an assembly injection-molding step with which one of the two components is manufactured in local positive engagement with the respective other component.

A vehicle door for a motor vehicle, including a support structure, an inner shell fixed to the support structure, and an outer panelling fixed to the inner shell. The inner shell is formed and connected to the support structure in such a way that it is a load-bearing component, thereby increasing the overall rigidity of the vehicle door.

A hood of a vehicle includes a rear beam, a front end module or grill opening reinforcement, a thermoplastic central cover extending between the rear beam and the front end module, the thermoplastic central cover comprising reinforcements along sides of the thermoplastic central cover between the rear beam and the front end module, the reinforcements protruding away from a top surface of the thermoplastic central cover, with a flange extending from a side of the reinforcement and fenders connected to the front end module and thermoplastic central cover, wherein each fender extends over a reinforcement and connects to a top surface of the thermoplastic central cover.

An exemplary fuel tank includes a plastic container and an integral composite heat shield. The plastic container has an outer layer formed from high-density polyethylene. The heat shield has a heat reflective layer, an attachment layer, and a non-woven insulation layer having a bonding portion that includes bi-component fibers. The outer layer of the plastic container permeates and bonds to at least a portion of bonding portion of the non-woven insulation layer.

An electric propulsion vehicle has a high voltage electric drive system and a low voltage electrical accessory system. A high voltage battery pack provides electrical power at a relatively higher voltage for a traction motor. A low voltage distribution system is routed within the vehicle carrying a relatively lower voltage for the accessory system. A molded battery enclosure contains the battery pack and extends between predetermined locations in the vehicle body/frame. The low voltage distribution system includes a bus bar retained in the enclosure and electrically isolated from the battery pack. The bus bar has exposed terminal ends accessible at the predetermined locations. Incorporating the low voltage bus bar into the high voltage battery enclosure reduces the packaging space for the low voltage distribution system while simultaneously strengthening the enclosure.

A leaf screen for an air intake of an HVAC system of a vehicle having a hood covering an engine compartment. The leaf screen includes a leaf screen body defining an air inlet opening covered by an integrally molded screen. A seal is integrally molded on a top surface of the leaf screen body in front of the air inlet opening. Bump-stops are integrally molded on the top surface that are engaged by an inner panel of the hood when closed. A method of making the leaf screen includes injecting a polymeric material into a mold to form a body portion. At least one elastomeric material is injected into the mold on one side of the body portion to form a seal and a plurality of bump-stops.

A roof module for a motor vehicle comprises an RTM frame and a Class-A covering layer, which at least partially covers the frame and is made of polyurethane. A method for manufacturing a roof module comprises the following steps: Initially, a fiber mat is put into a first mold. Then, a reactive resin system is introduced into the closed mold and the resin cures, so that a blank is formed. The blank is put into a second mold, into which subsequently polyurethane is introduced in the open condition. The polyurethane expands, wherein it at least partially forms a Class-A surface.

A resilient or flexible skirt panel assembly having an integral bracing system is disclosed. In operation, the bracing system need not attach to a trailer base rail. The innovation discloses straight, straight-angled and curved skirt panel orientations. Additionally, angled braces, v-braces, v-wings, and integral rib bracing mechanisms are disclosed. In aspects, the skirt panel and bracing mechanisms can absorb (or bend) under force while effectively having a memory to return to their original shape upon removal of the force. The skirt assembly can include a hem along the bottom edge of the skirt panel thereby enhancing performance and longevity of the assembly. Additionally, an anti-skid clamping assembly can be employed to connect the skirt assemblies to the trailer I-beam, base rail or cross-members.

A wind deflector for a vehicle roof having a displaceable cover element. The wind deflector can have an unfoldable deflector element made of a flat flexible material and whose lower edge portion can be fastened to a vehicle-mounted base via a lower edge strip and whose upper edge portion is fastened to a pivotable deploying bow via an upper edge strip. The lower edge strip and the vehicle-mounted base and/or the upper edge strip and the deploying bow can form a respective fastening system. The fastening system may have a fixing rib on one side and an arrangement of tabs attached to the fixing rib on the other side, the arrangement of tabs being formed by locking tabs and support tabs alternating along the fixing rib, the locking tabs and the support tabs being in contact with the fixing rib on sides facing away from each other.

A vehicle body includes a rocker panel elongated along an axis. The vehicle body includes a pillar fixed to the rocker panel and elongated in a direction transverse to the axis. The rocker panel includes a first flange and a second flange. The first flange and the second flange are on opposite sides of the pillar and spaced from each other in a direction parallel to the axis. The vehicle body includes a reinforcement fixed to the first and second flanges.