Abstract: A recyclable, low cost, collision-resistant automobile chassis and body and method for fabricating the same. The method of manufacture comprises; fabricating a plurality of generally planar bulkheads from a metal alloy; disposing the bulkheads in a generally and mutually parallel orientation, each bulkhead perpendicular to and aligned generally transversely and symmetrically relative to a common central horizontal longitudinal axis; fabricating a plurality of chassis segments from the metal alloy, each segment comprising a multiplicity of spaced hollow cells fixed at one end in a common surface; interposing and rigidly attaching at least one of said pluralities of chassis segments between respective bulkheads to form a plurality of chassis sections, a section defined as the portion of the fabricated chassis between two adjacent bulkheads; and permeating the plurality of chassis sections with liquefied polymer between and around said hollow cells.

Abstract: An automobile chassis and a one-piece body integrated into a unitary structure, and a method for fabricating, assembling and integrating the chassis and body. The body includes interior panels, a cockpit, an engine enclosure module, and an underbody. The chassis/body structure, comprised of a single type of aluminum alloy and a single type of thermoplastic, is resistant to high-stress loads and is substantially recyclable into industrial-quality constituents. A first preferred embodiment includes a body rotomolded from a reinforced polycarbonate, polycarbonate/ABS blend, or polyimide thermoplastic, seven aluminum alloy bulkheads, and stacks of thin-wall aluminum honeycomb-cell panels embedded in an unreinforced foam of the thermoplastic. A second preferred embodiment includes a body rotomolded from a reinforced liquid crystal polymer thermoplastic, seven aluminum alloy bulkheads, and stacks of thin-wall aluminum honeycomb panels.

Abstract: An ultra safe, low cost, ultra-low emissions automobile providing high survivability in case of an accident, the automobile having a cold molded engineered ceramic monocoque inner chassis body, and a stylized outer body encasing the inner body, the outer body being attached to the inner body. The automobile is constructed such that the inner chassis body is made up of at least two separately molded parts, and the two molded parts are joined together by self-aligning pin and hole combinations, each such combination including a pin projecting from one of the molded parts and a mating hole on the adjacent molded part. The molded parts of the inner body and each pin and mating hole combination are secured together by super glue. The inner body is shaped to accommodate a cockpit module, has a forward nose cell, and comprises a mass of structural plastic foam within the nose cell forming a collision bulkhead.