Abstract: A chassis assembly having mixed material for reduced mass is provided. The assembly comprises an upper structure comprised of metal. The upper structure has a plurality of first bond surfaces, each of which is parallel with each other at varying elevations relative to a z-axis of a 3-dimensional coordinate thereof. The assembly further comprises a lower structure made of a polymer composite. The lower structure has a plurality of second bond surfaces, each of which is parallel with each other at varying elevations relative to the z-axis thereof. The second bond surfaces are arranged to align with the first bond surfaces in complementing relation such that the lower structure is joined with the upper structure at the first and second bond surfaces. The assembly further comprises an adhesive disposed between the first and second bond surfaces to join the lower and upper structures at the first and second bond surfaces, defining a bond gap between the first and second bond surfaces.

Abstract: A chassis assembly having mixed material for reduced mass is provided. The assembly comprises an upper structure comprised of metal. The upper structure has a plurality of first bond surfaces, each of which is parallel with each other at varying elevations relative to a z-axis of a 3-dimensional coordinate thereof. The assembly further comprises a lower structure made of a polymer composite. The lower structure has a plurality of second bond surfaces, each of which is parallel with each other at varying elevations relative to the z-axis thereof. The second bond surfaces are arranged to align with the first bond surfaces in complementing relation such that the lower structure is joined with the upper structure at the first and second bond surfaces. The assembly further comprises an adhesive disposed between the first and second bond surfaces to join the lower and upper structures at the first and second bond surfaces, defining a bond gap between the first and second bond surfaces.

Abstract: An exemplary side impact system for a vehicle includes an energy absorption member including a first portion, a second portion, a third portion, and a fourth portion, the first and second portions connected by a first arcuate portion, the second and third portions connected by a second arcuate portion, and the third and fourth portions connected by a third arcuate portion such that the energy absorption member has a W-shaped cross-section and a load path distribution member. The load path distribution member is coupled to the energy absorption member at the first and third arcuate portions.

Abstract: An exemplary side impact system for a vehicle includes an energy absorption member including a first portion, a second portion, a third portion, and a fourth portion, the first and second portions connected by a first arcuate portion, the second and third portions connected by a second arcuate portion, and the third and fourth portions connected by a third arcuate portion such that the energy absorption member has a W-shaped cross-section and a load path distribution member. The load path distribution member is coupled to the energy absorption member at the first and third arcuate portions.

Abstract: An exemplary step assembly for a vehicle includes an energy absorption member including a support portion and a connection portion, the support portion including a support surface and a support structure, the support structure including a plurality of support members, the plurality of support members coupled to upper and lower inner walls of the support structure and a mounting member including a horizontal support member defining a plurality of openings. The energy absorption member is coupled to the mounting member with a mechanical fastener.

Abstract: A vehicle chassis structure includes a clamshell assembly, a third member, and a structural adhesive. The clamshell assembly includes a first member having a first concave surface and a second member having a second concave surface. The third member includes a convex face opposed by the first and second concave surfaces. The structural adhesive is disposed between, and in contact with, the first concave surface and the convex face, and is disposed between, and in contact with, the second concave surface and the convex face.

Abstract: A load management assembly can manage and/or absorb the energy from an external force applied to a vehicle. The load management assembly includes a frame rail and a mounting bracket coupled to the frame rail. In addition, the load management assembly includes a shield coupled to the frame rail. The shield partly surrounds the mounting bracket in order to protect the mounting bracket from an external force and to redirect a load path of the external force. The load management assembly may further include a reinforcement bracket to assist in directing the load path of the external force. The reinforcement bracket is coupled to the frame rail and may be in contact with the mounting bracket.

Abstract: A load management assembly can manage and/or absorb the energy from an external force applied to a vehicle. The load management assembly includes a frame rail and a mounting bracket coupled to the frame rail. In addition, the load management assembly includes a shield coupled to the frame rail. The shield partly surrounds the mounting bracket in order to protect the mounting bracket from an external force and to redirect a load path of the external force. The load management assembly may further include a reinforcement bracket to assist in directing the load path of the external force. The reinforcement bracket is coupled to the frame rail and may be in contact with the mounting bracket.

Abstract: A vehicle includes an underbody and a cradle assembly. The assembly includes a cradle body and a flange extending to a distal end portion. The distal end portion includes a platform having at least one side and defining an aperture spaced from the side. A fastener is disposed through the aperture and in engagement with the underbody when the cradle body is in a first position. The platform defines a void and has a portion of material disposed adjacent to the void to present a release pathway. The cradle body is configured to move from the first position to a second position which separates the flange of the cradle body from the underbody by moving the fastener out of the aperture, through the void and the portion of material along the release pathway, and out the side of the platform when the cradle body moves to the second position.

Abstract: A vehicle includes an underbody and a cradle assembly. The assembly includes a cradle body and a flange extending to a distal end portion. The distal end portion includes a platform having at least one side and defining an aperture spaced from the side. A fastener is disposed through the aperture and in engagement with the underbody when the cradle body is in a first position. The platform defines a void and has a portion of material disposed adjacent to the void to present a release pathway. The cradle body is configured to move from the first position to a second position which separates the flange of the cradle body from the underbody by moving the fastener out of the aperture, through the void and the portion of material along the release pathway, and out the side of the platform when the cradle body moves to the second position.

Abstract: A load transfer apparatus for a vehicle includes a first deflector member that is securable both to a body mount bracket that extends from a frame rail and to the frame rail so that a first portion of the frame rail is between the body mount bracket and the bumper, and a second portion of the frame rail is between the body mount bracket and the first deflector member. The first deflector member at least partially forms a load path from the bumper to the frame rail under a sufficient offset load applied to the bumper. The load transfer apparatus may also include a second deflector member securable to the bumper to extend from the bumper such that the second deflector member is spaced from and free from contact with the body mount bracket and the first deflector member prior to application of the sufficient offset load to the bumper.

Abstract: A load transfer apparatus for a vehicle includes a first deflector member that is securable both to a body mount bracket that extends from a frame rail and to the frame rail so that a first portion of the frame rail is between the body mount bracket and the bumper, and a second portion of the frame rail is between the body mount bracket and the first deflector member. The first deflector member at least partially forms a load path from the bumper to the frame rail under a sufficient offset load applied to the bumper. The load transfer apparatus may also include a second deflector member securable to the bumper to extend from the bumper such that the second deflector member is spaced from and free from contact with the body mount bracket and the first deflector member prior to application of the sufficient offset load to the bumper.

Abstract: A cross member for an automotive chassis structure includes a first portion and a second portion. The first portion extends along a longitudinal axis, and includes a generally U-shaped cross section perpendicular to the longitudinal axis. The second portion extends along the longitudinal axis, and includes a generally inverted U-shaped cross section perpendicular to the longitudinal axis. The first portion and the second portion are attached together to define a tubular structure that extends along the longitudinal axis, and defines a hollow interior region. The first portion and the second portion each include and are manufactured from a thermoplastic material reinforced with carbon fiber.

Abstract: A cradle for mounting an engine in a vehicle has left and right side members, and a rear cross member and front cross member extending between the left and right side members. The cradle has left and right front body mounts. Left and right deflector devices are mounted respectively on the cradle adjacent the left and right body mounts and forwardly of the vehicle wheels. Each of the left and right deflector devices including an impact receiving member that projects outwardly and rearwardly from the cradle to receive an impact load offset outboard from the body mounts. Each impact receiving member has an upper and lower sheet metal shell providing a top wall welded to a top wall of the cradle and a bottom wall welded to the bottom wall of the cradle, and a front impact receiving wall extending vertically between the top wall and the bottom wall.

Abstract: A cradle for mounting an engine in a vehicle has left and right side members, and a rear cross member and front cross member extending between the left and right side members. The cradle has left and right front body mounts. Left and right deflector devices are mounted respectively on the cradle adjacent the left and right body mounts and forwardly of the vehicle wheels. Each of the left and right deflector devices including an impact receiving member that projects outwardly and rearwardly from the cradle to receive an impact load offset outboard from the body mounts. Each impact receiving member has an upper and lower sheet metal shell providing a top wall welded to a top wall of the cradle and a bottom wall welded to the bottom wall of the cradle, and a front impact receiving wall extending vertically between the top wall and the bottom wall.

Abstract: A collapsible tow hook for a motor vehicle includes a bracket attached to a vehicle structure and having laterally spaced side walls with first and second slots in each of the side walls. A tow loop has laterally spaced arms that straddle the spaced side walls of the bracket. First and second bolts extend through bolt holes in the laterally spaced arms and through the slots of the side walls. A retainer acts between the bracket and the first and second bolts to establish a normal upward position of the tow loop on the vehicle. The retainer yields to allow the first and second bolts to traverse the slots upon the imposition of a load on the tow loop in a direction opposite to the towing direction so that the tow loop is pivoted to a collapsed position relative to the vehicle structure.

Abstract: A member is characterized by an external form, a length, and a boxed cross-section having a substantially uniform shape along the length of the member. The member includes a single joining portion arranged along the length of the member to maintain each of the external form and the boxed cross-section. The member additionally includes two fastening portions, each of the fastening portions arranged proximate to each end of the length, and each fastening portion configured for attachment to one of two substantially parallel rails spaced apart by a distance. The member is configured such that the length is sufficient to span the distance. Additionally, the member is formed out of high-grade steel by a process that enables the use of high-grade steel without employing a re-strike operation to alleviate material spring-back.

Abstract: A method of constructing vehicle frames of varying lengths from a flexible modular architecture is provided. The method comprises: providing substantially identical front and rear modules, and providing middle modules with constant-section longitudinal rails that are formable to a variety of desired lengths. The components are selected by trimming or forming a first middle module to a first longitudinal length and selecting one each of the substantially identical front and rear modules. A first frame, having a first frame length, is then assembled from the formed first middle module and substantially identical front and rear modules. After forming another middle module to a second length; a second frame, having a different frame length, may then be assembled from the second formed middle module and a second pair of substantially identical front and rear modules. An assembly for constructing frames of varying lengths from a flexible modular architecture is also provided.

Abstract: A welded joint includes a cross member, a web having an extruded hole that extends through a thickness of the web and conforms to a cross sectional shape of the cross member, a collar surrounding the hole, formed from material extruded from the web in a direction such that the collar extends along the cross member and away from the web, the cross member extending through the hole and into the collar, and a weld for mutually connecting the collar and the cross member.

Abstract: A longitudinal member assembly having a primary loading direction, including an interior longitudinal member and an exterior longitudinal member, and a method of assembly, is disclosed. The interior longitudinal member has a boxed-section shape including a first side and an opposed second side parallel to the first side. The exterior longitudinal member has a boxed shape including a first exterior side and an opposed second exterior side parallel to the first exterior side. The interior member is telescopically received in the exterior member creating an overlap area, the first exterior side includes a first side welding hole, and the second exterior side includes a second side welding hole. A first side hole weld extends around the first side welding hole, and a second side hole weld extends around the second side welding hole. The first and second holes are parallel to the primary loading direction.