Abstract: A vehicle floor structure includes a cross member having a substantially constant cross section shape. A spacing member is disposed beneath the cross member for securing to a chassis frame. The spacing member is positioned relative to the cross member to define an enclosed cavity between the spacing member and the cross member. The floor structure also includes a first collar affixed within the enclosed cavity. A fastener extends through the spacing member and the cross member, and compresses the first collar when the floor structure is secured to the chassis frame.

Abstract: A vehicle is provided. The vehicle includes a door that has a swing radius, a light-field camera, and a controller. The light-field camera is configured to detect the presence of an object within the swing radius of the door. The controller is programmed to prevent the door from transitioning between an opened position and a closed position in response to the light-field camera detecting the presence of an object in the swing radius of the door.

Abstract: A vehicle door has a swing radius, a light_field camera, and a controller. The light-field camera is configured to detect the presence of an object within the swing radius of the door. The controller is programmed to prevent the door from transitioning between an opened position and a closed position in response to the light-field camera detecting the presence of an object in the swing radius of the door.

Abstract: A door intrusion apparatus for a vehicle having a door and a rocker with a vertically extending wall defining a catcher opening. The apparatus includes a projection horizontally extending from the door and a projection trap attached to the vertically extending wall inside the rocker and below the catcher opening. In a side impact collision, the projection trap engages the projection thereby minimizing the door from intruding into a vehicle cabin.

Abstract: A sub-frame assembly supports a pair of wheels on a vehicle. The base may be an extrusion having a matrix of panels extending in a vertical direction. The sub-frame assembly has control arm brackets disposed on opposing ends of the base and attachment towers extending above the brackets providing attachment points to connect portions of an independent suspension to the vehicle and support a pair of wheels. The base, control brackets and attachment towers may be individual modular pieces. Left and right hand control brackets and attachment towers may be provided by respective unitary support pieces attached to opposing ends of the base. The unitary support pieces may be extrusions having panels extending in a transverse direction, nonaxial to the base. The base, control arm brackets and attachment towers, alternatively, may be provided by a single unitary extrusion having a matrix of panels extending in a transverse direction.

Abstract: A vehicle includes an external keypad, having a touchpad. The keypad may be configured to identify an access code according to user input to the touchpad, the access code including one of (i) a numerical value indicating a count of simultaneously pressed keys of the touchpad, and (ii) a swipe pattern including a press, slide, and release from the touchpad; and send the access code to a controller to facilitate access to a vehicle unlock user interface. The controller may direct the keypad to display the vehicle unlock user interface on the keypad when the access code matches a predefined access code stored to the controller. The keypad may display a background logo when the keypad is available to receive user input and may display a vehicle unlock user interface on the touchpad when the access code is validated.

Abstract: A sub-frame assembly for supporting a pair of wheels on a vehicle. The base may be an extrusion having a matrix of panels extending in a vertical direction. The sub-frame assembly has control arm brackets disposed on opposing ends of the base and attachment towers extending above the brackets providing attachment points to connect portions of an independent suspension to the vehicle and support a pair of wheels. The base, control brackets and attachment towers may be individual modular pieces. Left and right hand control brackets and attachment towers may be provided by respective unitary support pieces attached to opposing ends of the base. The unitary support pieces may be extrusions having panels extending in a transverse direction, nonaxial to the base. The base, control arm brackets and attachment towers, alternatively, may be provided by a single unitary extrusion having a matrix of panels extending in a transverse direction.

Abstract: A bi-directional element drive system includes a motor having a drive shaft, a cable anchor and a cable connector. The cable connector is carried on the drive shaft and has two ends connected to the cable anchor. In addition the drive system includes a support and a driven element. The driven element is displaced between a first position and a second position relative to the support by the motor.

Abstract: A cage assembly is provided to protect a battery pack in a vehicle. The cage assembly includes a top sub-assembly and a bottom sub-assembly that are secured together to protect the battery pack. U-shaped frames and base frames are connected together by tubular members. A method of making a cage for a battery pack of a vehicle is provided. The method may include assembling a first plurality of spaced tubes and a plurality of spaced inverted U-shaped frames to from a first sub-assembly. The method may also include assembling a second plurality of spaced tubes and a plurality of spaced frames to form a second sub-assembly. The first sub-assembly and the second sub-assembly may be assembled together to enclose the battery pack.

Abstract: A cage assembly is provided to protect a battery pack in a vehicle. The cage assembly includes a top sub-assembly and a bottom sub-assembly that are secured together to protect the battery pack. U-shaped frames and base frames are connected together by tubular members.

Abstract: A vehicle floor structure includes a cross member having a substantially constant cross section shape. A spacing member is disposed beneath the cross member for securing to a chassis frame. The spacing member is positioned relative to the cross member to define an enclosed cavity between the spacing member and the cross member. The floor structure also includes a first collar affixed within the enclosed cavity. A fastener extends through the spacing member and the cross member, and compresses the first collar when the floor structure is secured to the chassis frame.

Abstract: A roof bow for a vehicle is provided that has a “bow-tie” shape including a central portion flanked by two triangular portions. The triangular portions are joined to right and left roof brackets that are, in turn, joined to right and left roof rails. The bow-tie roof bow may be assembled from extruded tubular parts. The bow-tie roof bow may be assembled in a clamshell structure including an upper shell and a lower shell that are joined together by welding. The roof bow may be formed in one piece as a sheet metal stamping having side portions that are wider than the central portion.

Abstract: A roof bow for a vehicle is provided that has a “bow-tie” shape including a central portion flanked by two triangular portions. The triangular portions are joined to right and left roof brackets that are, in turn, joined to right and left roof rails. The bow-tie roof bow may be assembled from extruded tubular parts. The bow-tie roof bow may be assembled in a clamshell structure including an upper shell and a lower shell that are joined together by welding. The roof bow may be formed in one piece as a sheet metal stamping having side portions that are wider than the central portion.

Abstract: A sub-frame assembly for supporting a pair of wheels on a vehicle. The base may be an extrusion having a matrix of panels extending in a vertical direction. The sub-frame assembly has control arm brackets disposed on opposing ends of the base and attachment towers extending above the brackets providing attachment points to connect portions of an independent suspension to the vehicle and support a pair of wheels. The base, control brackets and attachment towers may be individual modular pieces. Left and right hand control brackets and attachment towers may be provided by respective unitary support pieces attached to opposing ends of the base. The unitary support pieces may be extrusions having panels extending in a transverse direction, nonaxial to the base. The base, control arm brackets and attachment towers, alternatively, may be provided by a single unitary extrusion having a matrix of panels extending in a transverse direction.

Abstract: A vehicle floor structure includes a cross member having a substantially constant cross section shape. A spacing member is disposed beneath the cross member for securing to a chassis frame. The spacing member is positioned relative to the cross member to define an enclosed cavity between the spacing member and the cross member. The floor structure also includes a first collar affixed within the enclosed cavity. A fastener extends through the spacing member and the cross member, and compresses the first collar when the floor structure is secured to the chassis frame.

Abstract: The present disclosure relates to various vehicle frame assemblies and methods of manufacturing the same. The vehicle frame assemblies have rails composed of dissimilar materials.

Abstract: A method of manufacturing a vehicle frame, includes: forming compatible threads on a first rail composed of a first material and a second rail composed of a second material; forming a pair of locators on the first and second rails, said locators configured to indicate an alignment condition of the first rail and second rail when screwed together; and screwing together the first rail and second rail.

Abstract: A door intrusion apparatus for a vehicle having a door and a rocker with a vertically extending wall defining a catcher opening. The apparatus includes a projection horizontally extending from the door and a projection trap attached to the vertically extending wall inside the rocker and below the catcher opening. In a side impact collision, the projection trap engages the projection thereby minimizing the door from intruding into a vehicle cabin.

Abstract: A roof bow for a vehicle is provided that has a “bow-tie” shape including a central portion flanked by two triangular portions. The triangular portions are joined to right and left roof brackets that are, in turn, joined to right and left roof rails. The bow-tie roof bow may be assembled from extruded tubular parts. The bow-tie roof bow may be assembled in a clamshell structure including an upper shell and a lower shell that are joined together by welding. The roof bow may be formed in one piece as a sheet metal stamping having side portions that are wider than the central portion.

Abstract: A vehicle body and a door intrusion resistance apparatus for a vehicle with a door that includes a protrusion and a rocker defining a receptacle that receives the protrusion when the door is closed. The door is inhibited from moving above the rocker by the protrusion being received in the receptacle that holds the door against the rocker in a side impact collision.