Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A body-on-frame vehicle includes a left frame rail, a right frame rail, a plate, a plurality of cross-members, a plurality of power storage modules, and a first electric motor. The plate is attached to both frame rails. The plurality of cross-members are attached to both frame rails. Adjacent cross-members cooperate with the plate and frame rails to define compartments. The plurality of power storage modules are disposed within a plurality of the compartments. The first electric motor is supported by a section of the frame rails forward or rearward of the power storage modules.

Abstract: This disclosure details electrified vehicles that are equipped with removable generators for increasing the electric range of the vehicles. An exemplary electrified vehicle includes a cargo space, such as a truck bed, and a generator removably positioned within the cargo space. The generator is adapted to selectively supply power for either charging a battery pack of the electrified vehicle or for propelling one or more vehicle drive wheels. In some embodiments, the generator is shaped like, and therefore disguised as, a toolbox.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A mounting rail assembly for mounting a seat to a vehicle is provided. The mounting rail assembly includes a substrate positioned between a first U-shaped track and a second U-shaped track in addition to one or more attachment members configured to couple the first and second U-shaped tracks and provide a clamping pressure to the substrate. The first and second U-shaped tracks include a plurality of apertures to receive the one or more attachment members.

Abstract: A mounting rail assembly for mounting a seat to a vehicle is provided. The mounting rail assembly includes a substrate positioned between a first U-shaped track and a second U-shaped track in addition to one or more attachment members configured to couple the first and second U-shaped tracks and provide a clamping pressure to the substrate. The first and second U-shaped tracks include a plurality of apertures to receive the one or more attachment members.

Abstract: A body-on-frame vehicle includes a left frame rail, a right frame rail, a plate, a plurality of cross-members, a plurality of power storage modules, and a first electric motor. The plate is attached to both frame rails. The plurality of cross-members are attached to both frame rails. Adjacent cross-members cooperate with the plate and frame rails to define compartments. The plurality of power storage modules are disposed within a plurality of the compartments. The first electric motor is supported by a section of the frame rails forward or rearward of the power storage modules.

Abstract: This disclosure details electrified vehicles that are equipped with removable generators for increasing the electric range of the vehicles. An exemplary electrified vehicle includes a cargo space, such as a truck bed, and a generator removably positioned within the cargo space. The generator is adapted to selectively supply power for either charging a battery pack of the electrified vehicle or for propelling one or more vehicle drive wheels. In some embodiments, the generator is shaped like, and therefore disguised as, a toolbox.

Abstract: A lower frame midrail structure for an automotive vehicle is formed from a pair of tubular members manufactured through a hydroforming process. The two tubular members are welded together in a longitudinally extending portion to provide support for the mounting structure of a bumper assembly. The joinder of the two tubular members creates a lower frame midrail cross-section that has a generally vertical internal web to strengthen and stiffen the midrail structure. The two tubular members laterally diverge from one another in a divergent zone in which the laterally spaced tubular members provide a stable interior and exterior support for a shock tower support member to be welded to the top of the tubular members. The hydroforming process can form openings in the sidewalls of the tubular members to permit passage of cross frame members to enhance the welding of the cross frame members to the midrail structure.

Abstract: An attachment mount apparatus connects a subframe component to the lower frame midrail structure for an automotive vehicle that is formed from a pair of tubular members manufactured through a hydroforming process. The two tubular members are formed with a pair of opposing semi-cylindrical depressions to receive a cylindrical mounting member internally of the frame structure. One of the semi-cylindrical depressions and the corresponding outer wall of the tubular member are pierced to receive the cylindrical mount and a mounting plate. The opposing semi-cylindrical depression serves as a stop to locate the cylindrical mount along the centerline of the frame structure. The mounting plate spans the entire frame structure and is supported on four wall thicknesses to provide a stable mount structure for subframe components. The cylindrical mounting member is threaded to receive a fastener for the mounting of the subframe member.

Abstract: An attachment mount apparatus connects a subframe component to the lower frame midrail structure for an automotive vehicle that is formed from a pair of tubular members manufactured through a hydroforming process. The two tubular members are formed with a pair of opposing semi-cylindrical depressions to receive a cylindrical mounting member internally of the frame structure. One of the semi-cylindrical depressions and the corresponding outer wall of the tubular member are pierced to receive the cylindrical mount and a mounting plate. The opposing semi-cylindrical depression serves as a stop to locate the cylindrical mount along the centerline of the frame structure. The mounting plate spans the entire frame structure and is supported on four wall thicknesses to provide a stable mount structure for subframe components. The cylindrical mounting member is threaded to receive a fastener for the mounting of the subframe member.

Abstract: A door system for an automotive vehicle includes an impact-responsive catcher pin which may be operated by a supplemental restraint system having side impact sensing capability so that the impact-responsive catcher pin may be directed to deploy from a housing mounted within a vehicle door, to a position in which the catcher pin locks the vehicle door to a rocker beam adjoining the door.

Abstract: A single component bumper beam and lower frame midrail structure, is formed through a hydroforming process to create a uniform “B-shaped” cross-sectional configuration with internal crash triggers to enhance crash performance. The mounting legs of the integral bumper structure are formed with a reduced cross-section at the terminal ends thereof to facilitate insertion into lower frame midrails formed from a pair of horizontally disposed tubes. The terminal end portions of the mounting legs are formed with a longitudinally extending slot to receive a central co-joined wall member formed through the welding of the two vertically oriented tubular members in the lower frame midrails. The single component bumper and longitudinally extending mounting leg structure can be formed by welding together two vertically oriented tubes.

Abstract: An attachment mount apparatus connects a subframe component to the lower frame midrail structure for an automotive vehicle that is formed from a pair of tubular members manufactured through a hydroforming process. The two tubular members are formed with a pair of opposing semi-cylindrical depressions to receive a cylindrical mounting member internally of the frame structure. One of the semi-cylindrical depressions and the corresponding outer wall of the tubular member are pierced to receive the cylindrical mount and a mounting plate. The opposing semi-cylindrical depression serves as a stop to locate the cylindricalal mount along the centerline of the frame structure. The mounting plate spans the entire frame structure and is supported on four wall thicknesses to provide a stable mount structure for subframe components. The cylindrical mounting member is threaded to receive a fastener for the mounting of the subframe member.

Abstract: A single component bumper beam and lower frame midrail structure, is formed through a hydroforming process to create a uniform “B-shaped” cross-sectional configuration with internal crash triggers to enhance crash performance. The mounting legs of the integral bumper structure are formed with a reduced cross-section at the terminal ends thereof to facilitate insertion into lower frame midrails formed from a pair of horizontally disposed tubes. The terminal end portions of the mounting legs are formed with a longitudinally extending slot to receive a central co-joined wall member formed through the welding of the two vertically oriented tubular members in the lower frame midrails. The single component bumper and longitudinally extending mounting leg structure can be formed by welding together two vertically oriented tubes.

Abstract: An attachment mount apparatus connects a subframe component to the lower frame midrail structure for an automotive vehicle that is formed from a pair of tubular members manufactured through a hydroforming process. The two tubular members are formed with a pair of opposing semi-cylindrical depressions to receive a cylindrical mounting member internally of the frame structure. One of the semi-cylindrical depressions and the corresponding outer wall of the tubular member are pierced to receive the cylindrical mount and a mounting plate. The opposing semi-cylindrical depression serves as a stop to locate the cylindricalal mount along the centerline of the frame structure. The mounting plate spans the entire frame structure and is supported on four wall thicknesses to provide a stable mount structure for subframe components. The cylindrical mounting member is threaded to receive a fastener for the mounting of the subframe member.

Abstract: A lower frame midrail structure for an automotive vehicle is formed from a pair of tubular members manufactured through a hydroforming process. The two tubular members are welded together in a longitudinally extending portion to provide support for the mounting structure of a bumper assembly. The joinder of the two tubular members creates a lower frame midrail cross-section that has a generally vertical internal web to strengthen and stiffen the midrail structure. The two tubular members laterally diverge from one another in a divergent zone in which the laterally spaced tubular members provide a stable interior and exterior support for a shock tower support member to be welded to the top of the tubular members. The hydroforming process can form openings in the sidewalls of the tubular members to permit passage of cross frame members to enhance the welding of the cross frame members to the midrail structure.

Abstract: A crush rail or other structural member of a vehicle is provided with crush triggers. The crush triggers are formed by heating localized areas of the crush rail or other part and allowing them to cool slowly to provide increased ductility and reduced strength in a localized region. The crush rail is designed to collapse in a series of convolutions in a regular and repeated pattern. Crush triggers may be provided on body pillars, steering columns, drive shafts, engine support cradles, and other parts of a vehicle. A plurality of crush triggers may be provided on a single structural member depending upon impact absorption requirements.