Abstract: A vehicle includes an integrated floor and traction battery support assembly. The assembly includes a floor panel and cross-members each having an upper portion attached to a lower surface of the floor panel and extending laterally across the floor panel. The assembly further includes a battery tray attached to lower portions of the cross-members and cooperating with the lower surface to define a battery-pack enclosure. A battery pack is disposed in the enclosure.

Abstract: A pillar for a vehicle is disclosed that includes an outer panel, an inner panel, and an extruded reinforcement attached between the inner and outer panels. The reinforcement extends from an upper end of the inner panel to a striker attachment area on the outer panel. A lower end of the reinforcement is trimmed to be spaced from the inner panel. The inner panel may be full height of the pillar or may extend from the rocker to the striker area where the inner panel overlaps the reinforcement. The reinforcement above the striker area may function as the inner panel above the striker area. A method is disclosed for making a B-pillar for a vehicle.

Abstract: A vehicle having a body including a roof supported between spaced roof rails. A plurality of roof bows extend between and are attached to the roof rails that reinforce the roof. The roof bows define an air distribution duct that includes an air inlet and at least one air vent. The air distribution duct defines a downwardly facing open channel that is closed by a headliner.

Abstract: A vehicle having a body including a roof supported between spaced roof rails. A plurality of roof bows extend between and are attached to the roof rails that reinforce the roof. The roof bows define an air distribution duct that includes an air inlet and at least one air vent. The air distribution duct defines a downwardly facing open channel that is closed by a headliner.

Abstract: A vehicle body structure includes spaced roof rails and a structural air duct. The air duct has at least two bows connecting between the roof rails and defining first and second channels. An interconnecting member is connected between the bows and defines a third channel connecting the first and second channels in fluid communication with each other. At least one of the bows defines an outlet port configured to supply air to a cabin.

Abstract: A composite structure includes a metallic plate and a cured-plastic sheet. The metallic plate has and an external boundary and a centrally located offset protruding towards a first side. The metallic plate defines at least one aperture extending through a thickness of the metallic plate. The cured-plastic sheet is secured to the first side of the metallic plate. The cured-plastic sheet extends beyond the boundary and into the at least one aperture.

Abstract: A method is provided for enhancing in-service structural performance of a sheet metal component incorporating a discontinuity. The method comprises heat-treating a zone of the sheet metal component a predetermined distance from the discontinuity thereby changing the strength and ductility of the zone and shifting the deformation induced in the sheet metal component by a subsequent deformation event away from the discontinuity to the zone.

Abstract: A vehicle body assembly includes an outer component defining a cavity. The outer component has a pair of first flanges. An inner component has a pair of second flanges each joined to one of the first flanges. A reinforcement formed of carbon fiber is disposed in the cavity between the components. The reinforcement includes a faceplate joined to the outer component with a rivet and third flanges each joined to the inner component with a rivet.

Abstract: A method is provided for enhancing in-service structural performance of a sheet metal component incorporating a discontinuity. The method comprises heat-treating a zone of the sheet metal component a predetermined distance from the discontinuity thereby changing the strength and ductility of the zone and shifting the deformation induced in the sheet metal component by a subsequent deformation event away from the discontinuity to the zone.

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 reinforced frame structure for a vehicle is provided. The frame structure includes a frame portion having a first portion and a pair of wall portions extending therefrom. A first reinforcement is rigidly coupled to the wall portions, and the first portion, the wall portions, and first reinforcement combine to define an enclosure.

Abstract: The present disclosure relates to methods of manufacturing vehicle frame assemblies. Some of the disclosed methods include forming a key and receptor arrangement between an interconnecting member, having a first material composition, and a cross-member, having a second material composition; attaching the interconnecting member and cross-member via the key and receptor arrangement at one location; inserting the interconnecting member and cross-member in a side rail; and welding the interconnecting member to the side rail at another location.

Abstract: The present disclosure relates to methods of manufacturing vehicle frame assemblies. Some of the disclosed methods include forming a key and receptor arrangement between an interconnecting member, having a first material composition, and a cross-member, having a second material composition; attaching the interconnecting member and cross-member via the key and receptor arrangement at one location; inserting the interconnecting member and cross-member in a side rail; and welding the interconnecting member to the side rail at another location.

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

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 reinforced frame structure for a vehicle is provided. The frame structure includes a frame portion having a first portion and a pair of wall portions extending therefrom. A first reinforcement is rigidly coupled to the wall portions, and the first portion, the wall portions, and first reinforcement combine to define an enclosure.

Abstract: A reinforced closed section assembly is provided wherein the assembly includes a closed section member defining a first hole on a first side and a second hole on a second side opposite the first side. The reinforced closed section assembly further includes a reinforcement member disposed within the first and second holes of the closed section member.

Abstract: A structure for transferring energy during an automotive front end impact includes an upper load path structure having a first shotgun rail a second shotgun rail and an upper radiator bar extending therebetween, a lower load path structure having a first side rail a second side rail and a lower support member extending therebetween. During an impact, the upper radiator bar is configured to transfer energy to the first and second shotgun rails, and the lower support member is configured to transfer energy to the first and second side rails during an impact.

Abstract: A sandwich panel for a vehicle is provided. The sandwich panel includes a first panel defining a plurality of apertures, and a second panel attached to the first panel. The second panel and the first panel define a cavity between the first panel and the second panel. Foam is disposed between the first panel and the second panel. The plurality of apertures of the first panel are operatively configured to receive a tool for pumping expandable foam in between the first panel and the second panel.

Abstract: A sandwich panel for a vehicle is provided. The sandwich panel includes a first panel defining a plurality of apertures, and a second panel attached to the first panel. The second panel and the first panel define a cavity between the first panel and the second panel. Foam is disposed between the first panel and the second panel. The plurality of apertures of the first panel are operatively configured to receive a tool for pumping expandable foam in between the first panel and the second panel.