Abstract: A row of docking stations to stow containers or trolleys is provided along at least one side of a van cargo storage area and a corridor for loading and unloading containers or trolleys individually or in groups from the rear of the van is provided. Preferably, the docking stations are automated. Interference with the storage and removal of containers or trolleys by the wheel wells of the vans or other vehicles is eliminated. Motorized mechanisms capture and lift the containers or trolleys above the level of the wheel wells for stowage in the docking stations to maximize the available storage area beyond that available on the floor of the cargo area. Individual containers or trolleys may be maintained in docking stations until needed.

Abstract: A vehicle tailgate assembly primarily for pick-up trucks comprises a frame with a transverse base and support arms extending perpendicularly therefrom adjacent distal ends of the base. A tailgate door is rotationally mounted to the frame between the support arms. The door comprises a transverse upper section rotationally joined to a transverse lower section at a rotational joint, preferably a hinge. A releasable locking mechanism is located adjacent the rotational joint to releasably hold the upper section in relation to the lower section at selected orientations. An additional locking mechanism may selectively hold the lower section and/or the upper section to the support arms. The tailgate may also be provided with an extendible tailgate which may be rotated interiorly and exteriorly of the plane of the upper section. An extendible handle may also be provided to support user entry and exit from a cargo hold of the truck.

Abstract: A process for preparing a multi-thickness welded steel vehicle rail, the process comprises the steps of: (a) forming a first tube having a first outer diameter, an inner diameter and a first wall thickness; (b) forming a second tube having the first outer diameter, a second inner diameter and a second wall thickness different than the first wall thickness; (c) swaging a first end of the first tube to a second outer diameter less than the second inner diameter of the second tube; (d) inserting the swaged first end of the first tube into an end of the second tube to form a joint; (e) welding the first tube and the second tube together to form a weld at the joint to form a tube blank with a heat affected zone of lower metal strength in the area of the weld; (f) preheating the tube blank to create a common crystalline microstructure along a length of the tube blank; (g) introducing the tube blank into a blow molding tool having inner molding walls; (h) molding the tube blank at an elevated temperature by expandin

Abstract: A vehicle tailgate assembly comprises a frame with a transverse base and support arms extending perpendicularly therefrom adjacent distal ends of the base, a central section also extending perpendicularly from the base but to a lesser extent than the support arms, a door rotationally mounted to the frame between the support arms, the door being profiled with a central opening matching the central section and aligned therewith in a co-planar manner when the door is in a fully closed position, a mating portion comprising an indentation in the door adapted to mate with the central section when the door is rotated 180 degrees from the fully closed position to a working position to expose the central opening with the door co-planar with the frame.

Abstract: A vehicle tailgate with an integrated collapsible door comprises a tailgate having an outer wall, an inner wall and a cavity there between, a door section of the tailgate having an inboard wall and an outboard wall and being moveable between a closed position and an open position substantially within the envelope of the tailgate, the inboard wall and the outboard wall being connected by a linkage to permit relative movement there between, a first track to guide the motion of the inboard wall and a second track to guide the motion of the outboard wall, and a power drive unit to power the motion of the door section, such that in the closed position of the door section the inboard wall is flush with the inner wall of the tailgate and the outboard wall is flush with the outer wall of the tailgate, and in the open position of the door section at least a portion of the inboard wall and at least a portion of the outboard wall lie within the cavity between the outer wall and the inner wall of the tailgate.

Abstract: A vehicle tailgate with an integrated collapsible door comprises a tailgate having an outer wall, an inner wall and a cavity there between, a door section located in an upper portion of the tailgate having an inboard wall and an outboard wall and being moveable between a closed position and an open position substantially within an envelope of the tailgate, the door section comprising means to vary the spacing between the inboard wall and the outboard wall, the means to vary the spacing between the inboard wall and the outboard wall comprising at least one rotatable cam element located within the door section, such that when the door section is in the closed position the inboard wall is flush with the inner wall and the outboard wall is flush with the outer wall and when the door section is in the open position the spacing between the inboard wall and the outboard wall is reduced to allow a portion of the door section to be received in the cavity.

Abstract: A ball joint includes a stud extending from a ball. A housing has a bore that receives the ball. The housing has an interior surface facing the ball that includes a groove. A plastic bearing is arranged between the ball and the housing. The plastic bearing has first and second sides opposite one another. The first side has a spherical surface engaging the ball. The second side has a protrusion opposite the spherical surface that is received in and fills the groove and a recess in the spherical surface opposite the protrusion.

Abstract: A power drive module for a vehicle power door includes a housing, a drive mechanism arranged in the housing and configured to move a drive element, and a brake assembly arranged in the housing. The brake assembly includes a brake ring operatively coupled to the drive mechanism. A brake band is wrapped about the brake ring and movable between a normally engaged position relative to the brake ring and a disengaged position relative to the brake ring. A brake release actuator is operatively connected to the brake band and configured to move the brake band between the engaged and disengaged positions with the brake ring in response to an electrical signal.

Abstract: A door power drive module includes a housing and a motor arranged in the housing. First and second gearboxes are arranged in the housing and are coupled in series with one another by a shaft member. The first gearbox connects the motor to the second gearbox. An output shaft is coupled to the second gearbox. A brake assembly is selectively connected to the shaft member. The brake assembly has a normally closed position in which the shaft member is grounded to the housing. The brake assembly includes an open position corresponding to one of a door closing mode and a door opening mode. The shaft member is configured to be rotatable relative to the housing in the brake open position in response to the motor driving the first gearbox. The brake assembly includes a holding torque in the normally closed position. A torque is applied to the brake assembly above the holding torque that permits the shaft member to rotate in any direction of rotation.

Abstract: A method of actuating a door includes the steps of manually pivoting a door in a direction about a hinge to provide a manual input, detecting the manual input and energizing a motor to drive the door in the direction in response to the manual input. The manual door pivoting step includes exceeding a holding torque of a brake assembly that holds the door. The direction can be any direction for opening or closing the door.

Abstract: A door checker includes a housing which has a base from which first and second opposing flanges extend. First and second guide pins are spaced apart from one another and are interconnected to the first and second flanges. The first and second guide pins are configured to deflect in response to a load. A check arm extends through the base and is arranged between the first and second guide pins. The check arm is configured to move relative to the housing and includes a profile that corresponds to a variable door holding force. A bearing member is arranged on one side of the check arm and the bearing member coacts with the profile and is supported on the first and second guide pins and is configured to slide thereon in response to movement of the check arm relative to the bearing member. The bearing member transfers the load from the check arm to the first and second guide pins.

Abstract: A deployable vehicle rear wing conforms closely to the styled surface of the vehicle body in a retracted, or stowed, position while adaptively changing its cross section in a deployed position so as to provide a highly efficient airfoil section, with an integrated Gurney flap. Additionally, the adaptive cross section changes and Gurney flap deployment is provided via a linkage that utilizes a drive mechanism of a main deployment system.

Abstract: A method of operating a vehicle door includes the step of pushing an unlatched door to an ajar position. The unlatched door is mechanically held in the ajar position. In one embodiment, the method is performed using a door presenting system that includes a door checker that is configured to hold a door in the ajar position. A presenting actuator is movable between retracted and extended positions. The extended position corresponds to the ajar position. A controller is configured to move the presenting actuator between the retracted and extended positions in response to a presenting signal.

Abstract: A selectively switchable dual rate vehicle suspension system comprising a pushrod actuated inboard spring configuration, conventionally oriented between the unsprung mass and the sprung mass of one corner of the vehicle, comprising a torsion bar spring of a first predetermined rate, K1, and a coil spring of a second predetermined rate, K2, arranged in series so as to provide a total combined spring rate KT.

Abstract: An automotive door system includes a hinge that supports a door. A switch provides a first input in response to a user request to automatically open or close the door. An output shaft of a power drive module is connected to the door and a gearbox to provide an output torque that corresponds to a desired motion of the door about the hinge. A brake assembly is connected to a shaft member and has a normally closed position in which the shaft member is grounded to the housing and an open position that corresponds to one of a door closing mode and a door opening mode. A position sensor detects rotation of the output shaft and provides a second input in response thereto, which corresponds to a manually initiated movement of the door that exceeds a slip torque of the brake assembly in the normally closed position.

Abstract: A door checker includes a housing which has a base from which first and second opposing flanges extend. First and second guide pins are spaced apart from one another and are interconnected to the first and second flanges. A check arm extends through the base and is arranged between the first and second guide pins. The check arm is configured to move relative to the housing and includes a profile that corresponds to a variable door holding force. A bearing member is arranged on one side of the check arm and is slidably supported by the first and second guide pins. The bearing member coacts with the profile.

Abstract: A pedestrian protection automotive hinge includes a release assembly which includes a clip supported at one of the first and second opposing ends of a slot in one of first and second members, and a stop pin supported by the other of the first and second members. The stop pin is captured in the clip in the normally closed position and the normally opened position. An actuator is configured to engage the second member and to force the second member upward relative to the first member in response to a collision input. The stop pin is configured to break the clip in response to this force permitting the second member to pivot about a member pin relative to the first member to an opened hood collision position and the stop pin to move to the end of the slot opposite the clip.

Abstract: An automotive door system includes a hinge supporting a door. A door check module interconnects to one of the vehicle and the door by a linkage assembly. An output shaft is connected to the linkage assembly and rotates relative to a door check module housing. The output shaft provides an output torque to check the door in a desired door position. A sensor detects rotation of the shaft and produces a signal in response thereto. A brake assembly includes a shaft member operatively connected to the output shaft. The brake assembly has a normally closed position in which the shaft member is grounded to the housing in a door check mode. The brake assembly includes an open position that corresponds to one of a door closing mode and a door opening mode. The brake assembly moves from the normally closed position to the open position in response to the signal.

Abstract: A method is provided which forms a closed section hollow structural element by performing the following steps which include press forming an upper sheet metal component configured with two primary parallel downstanding interface flanges; press forming a lower sheet metal component configured with two primary parallel upstanding interface flanges; complementarily trimming the downstanding interface flanges and the upstanding interface flanges using five-axis laser cutting; and butt welding the interface flanges of the upper and lower sheet metal components to one another to form a continuous hollow structural element of variable cross section.

Abstract: A spoiler mechanism (13) for a vehicle (10) includes a spoiler (16) that has a stowed position and first and second deployed positions. An actuator (22) is configured to move the spoiler (16) though the stowed and first and second deployed positions in response to a command. A multi-link assembly (20) is interconnected by pivot points. The multi-link assembly (20) is operatively connected to the spoiler (16). In the first deployed position at least three pivot points are aligned with one another in a plane and provide a first geometrically locked position. In the second deployed position a second geometrically locked position is provided in which a link of the multi-link assembly (20) abuts another structure.