Abstract: A roof support for a vehicle is provided containing a first side roof rail; a transverse roof bow fixed to and extending from the first side roof rail; and a first brace fixed to the first side roof rail at a forward point on the first side roof rail, wherein the first brace extends to the transverse roof bow and is fixed to a first aft point on the transverse roof bow, thereby advantageously defining a first angle between the first side roof rail and the first brace. The roof support may further include a second side roof rail opposite the first side roof rail such that the roof bow laterally extends from the first side roof rail to the second side roof rail, wherein a second brace is connected in like manner.

Abstract: A roof support for a vehicle is provided containing a first side roof rail; a transverse roof bow fixed to and extending from the first side roof rail; and a first brace fixed to the first side roof rail at a forward point on the first side roof rail, wherein the first brace extends to the transverse roof bow and is fixed to a first aft point on the transverse roof bow, thereby advantageously defining a first angle between the first side roof rail and the first brace. The roof support may further include a second side roof rail opposite the first side roof rail such that the roof bow laterally extends from the first side roof rail to the second side roof rail. A second brace may be fixed to the second side roof rail at a forward point thereof, whereby the second brace also extends to the roof bow and is fixed to a second aft point thereof, thereby defining a second angle between the second side roof rail and the second brace.

Abstract: A one-piece shotgun is configured to absorb impact energy when a front of the vehicle is impacted. The shotgun comprises an upper portion, a mid portion, and a lower portion, the upper portion having an end configured to connect to a hinge pillar; and a Z-trigger formed by two indentations and being located adjacent the upper portion end. The indentations of the Z-trigger are located on an outer side and an inner side of the shotgun to cause substantially lateral bending when sufficient force is applied to the shotgun.

Abstract: A method of forming a flanged tubular member includes the steps of: positioning a tubular blank in a die; applying nominal pressure; closing the dies; and increasing pressure within the blank, thereby converting the tubular blank to a hydroformed member having the flange and a hem with a cavity therein. The die halves define: a die tubular cavity portion; a die hem cavity portion; and a die flange cavity portion. Upon closing the die halves with nominal pressure and then increasing pressure, (1) the blank is deformed within the die tubular cavity portion; (2) the flange is defined from a portion of the blank in the die flange cavity portion; and (3) at least an intermediate hem is defined in the die hem cavity portion.

Abstract: A one-piece shotgun is configured to absorb impact energy when a front of the vehicle is impacted. The shotgun comprises an upper portion, a mid portion, and a lower portion, the upper portion having an end configured to connect to a hinge pillar; and a Z-trigger formed by two indentations and being located adjacent the upper portion end. The indentations of the Z-trigger are located on an outer side and an inner side of the shotgun to cause substantially lateral bending when sufficient force is applied to the shotgun.

Abstract: A one-piece shotgun is configured to absorb impact energy when a front of the vehicle is impacted. The shotgun comprises an upper portion, a mid portion, and a lower portion, the upper portion having an end configured to connect to a hinge pillar; and a Z-trigger formed by two indentations and being located adjacent the upper portion end. The indentations of the Z-trigger are located on an outer side and an inner side of the shotgun to cause substantially lateral bending when sufficient force is applied to the shotgun.

Abstract: A method of forming a flanged tubular member includes the steps of: positioning a tubular blank in a die; applying nominal pressure; closing the dies; and increasing pressure within the blank, thereby converting the tubular blank to a hydroformed member having the flange and a hem with a cavity therein. The die halves define: a die tubular cavity portion; a die hem cavity portion; and a die flange cavity portion. Upon closing the die halves with nominal pressure and then increasing pressure, (1) the blank is deformed within the die tubular cavity portion; (2) the flange is defined from a portion of the blank in the die flange cavity portion; and (3) at least an intermediate hem is defined in the die hem cavity portion.

Abstract: A one-piece shotgun is configured to absorb impact energy when a front of the vehicle is impacted. The shotgun comprises an upper portion, a mid portion, and a lower portion, the upper portion having an end configured to connect to a hinge pillar; and a Z-trigger formed by two indentations and being located adjacent the upper portion end. The indentations of the Z-trigger are located on an outer side and an inner side of the shotgun to cause substantially lateral bending when sufficient force is applied to the shotgun.

Abstract: A hydroformed tubular frame member includes an internal bulkhead member that is formed during the hydroforming process during which the frame member is manufacture from tubular stock material. The internal bulkhead is cut from one face by piercing three sides of a weld access opening with the die in which the tubular frame member is formed during the hydroforming process. The bulkhead member is then bent along the fourth side of the weld access opening and shaped into a folded configuration that includes a vertical portion spanning the distance between the opposing faces of the frame member, and a horizontal portion to facilitate welding to the opposing face. The provision of the internal bulkhead member increases stiffness in the tubular frame member and reduces the matchboxing effect associated with hydroformed tubular frame members. The frame member with internal bulkhead is particularly advantageous in manufacturing an automotive frame.

Abstract: An automotive vehicle frame element includes a generally S shaped forward rail having a forward rail portion and a structurally reinforced rear rail portion substantially longitudinally displaced therefrom and a fold inducing area therebetween, a toe pan attached to the rail having a front wall projecting perpendicularly therefrom, the front wall having a point of separation from the rail at a location between the forward and rear rail portions, and the fold inducing area located longitudinally forward of the point of separation of the toe pan portion from the rail and at the point where the structurally reinforced rear rail portion transitions into the forward rail portion.