Abstract: A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A method of joining first and second vehicle components to make an assembly includes applying structural adhesive and mastic to the first component. The first and second component may be made of different metals, and are brought together and joined at an interface using a linkage. Thereafter, the structural adhesive and mastic are cured. The mastic seals an interior edge of the interface, which is located at an interior of the assembly. A dust sealer is applied and cured to seal the exterior edge of the interface, which is located at an exterior of the assembly. The method results in sealing of all the edges around the entire perimeter of the interface, thus inhibiting water intrusion into the interface and possible corrosion resulting therefrom.

Abstract: A method of joining first and second vehicle components to make an assembly includes applying structural adhesive and mastic to the first component. The first and second component may be made of different metals, and are brought together and joined at an interface using a linkage. Thereafter, the structural adhesive and mastic are cured. The mastic seals an interior edge of the interface, which is located at an interior of the assembly. A dust sealer is applied and cured to seal the exterior edge of the interface, which is located at an exterior of the assembly. The method results in sealing of all the edges around the entire perimeter of the interface, thus inhibiting water intrusion into the interface and possible corrosion resulting therefrom.

Abstract: A multi-material joint and a method of making thereof. The multi-material joint includes a first member comprising a first metal or metal alloy that is secured to a second member comprising a second metal or metal alloy that is different than the first metal or metal alloy. A sealant is positioned between the first member and the second member that galvanically insulates the first member from the second member. The sealant comprises a liquid elastomer and a foaming agent.

Abstract: A multi-material joint and a method of making thereof. The multi-material joint includes a first member comprising a first metal or metal alloy that is secured to a second member comprising a second metal or metal alloy that is different than the first metal or metal alloy. A sealant is positioned between the first member and the second member that galvanically insulates the first member from the second member. The sealant comprises a liquid elastomer and a foaming agent.

Abstract: A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A vehicle assembly method includes providing an aluminum roof component including a peripheral flange structure that defines a roof adhesive bonding zone; providing a steel vehicle body component including a body adhesive bonding zone; removably fastening the roof component to the vehicle body component with the peripheral flange structure spaced from the vehicle body component; electrocoating the roof component secured to the vehicle body component including the roof adhesive bonding zone and the body adhesive bonding zone; painting the roof component secured to the vehicle body component; removing the painted roof component from the painted vehicle body component; applying an adhesive that is curable at room temperature to at least one of the roof adhesive bonding zone and the body adhesive bonding zone; securely fastening the painted roof component to the painted vehicle body component with the adhesive spanning the adhesive bonding zones; and curing the adhesive.

Abstract: A method of joining first and second vehicle components to make an assembly includes applying structural adhesive and mastic to the first component. The first and second component may be made of different metals, and are brought together and joined at an interface using a linkage. Thereafter, the structural adhesive and mastic are cured. The mastic seals an interior edge of the interface, which is located at an interior of the assembly. A dust sealer is applied and cured to seal the exterior edge of the interface, which is located at an exterior of the assembly. The method results in sealing of all the edges around the entire perimeter of the interface, thus inhibiting water intrusion into the interface and possible corrosion resulting therefrom.

Abstract: A vehicle assembly method includes providing an aluminum roof component including a peripheral flange structure that defines a roof adhesive bonding zone; providing a steel vehicle body component including a body adhesive bonding zone; removably fastening the roof component to the vehicle body component with the peripheral flange structure spaced from the vehicle body component; electrocoating the roof component secured to the vehicle body component including the roof adhesive bonding zone and the body adhesive bonding zone; painting the roof component secured to the vehicle body component; removing the painted roof component from the painted vehicle body component; applying an adhesive that is curable at room temperature to at least one of the roof adhesive bonding zone and the body adhesive bonding zone; securely fastening the painted roof component to the painted vehicle body component with the adhesive spanning the adhesive bonding zones; and curing the adhesive.

Abstract: A method of joining a first body made of a first material to a second body made of a second material is disclosed. The method includes the steps of placing an adhesive between the first body and second body, moving the first body toward and into contact with the second body with the adhesive between the first body and the second body, pre-curing the adhesive, and curing the first body and second body in an oven. Pre-curing may be done by induction curing along a bonding line, pre-curing adhesive in a low temperature oven, or using a two-part adhesive.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A method of joining a first body made of a first material to a second body made of a second material is disclosed. The method includes the steps of placing an adhesive between the first body and second body, moving the first body toward and into contact with the second body with the adhesive between the first body and the second body, pre-curing the adhesive, and curing the first body and second body in an oven. Pre-curing may be done by induction curing along a bonding line, pre-curing adhesive in a low temperature oven, or using a two-part adhesive.

Abstract: A joint includes a first body, a second body, and an adhesive. The first body includes a coated portion and an uncoated portion. The second body includes a coated portion and an uncoated portion. The adhesive is positioned on the uncoated portion of each of the first and second bodies. The adhesive is expandable to cover at least a part of the coated portion of each of the first and second bodies. The first body and the second body can be fabricated for dissimilar materials. The adhesive includes insulating properties that can insulate the first body from the second body to inhibit galvanic corrosion. During a method of forming a joint between a first body and a second body, the adhesive can be at least partially cured so as to hold the first body and second body in the proper relative alignment during the formation process.