Abstract: The present disclosure describes a vehicle including an inner wheelbase panel, a first panel, a second panel and a pillar that is coupled to the wheelbase panel. The pillar includes a wall, a first flange, a second flange, and a tunnel. The wall defines an inner cavity and an outer cavity. The first flange extends outwardly from the wall and the second flange extends inwardly from the wall. The vehicle includes baffle which extends through the tunnel and is sized and shaped to seal both the inner cavity and the outer cavity.

Abstract: A vehicle body includes a rocker panel elongated along an axis. The vehicle body includes a pillar fixed to the rocker panel and elongated in a direction transverse to the axis. The rocker panel includes a first flange and a second flange. The first flange and the second flange are on opposite sides of the pillar and spaced from each other in a direction parallel to the axis. The vehicle body includes a reinforcement fixed to the first and second flanges.

Abstract: A vehicle C-pillar assembly including a C-pillar, a rear quarter extension, and a rocker panel is provided. The rear quarter extension mounts to the C-pillar and includes an arc portion. The rocker panel mounts to the rear quarter extension to define a horizontal joint therebetween and includes a notch providing space for the arc portion to extend upward along the C-pillar. The rocker panel may include an end and the rocker panel may be secured to the C-pillar so that the end extends rearward of the C-pillar to contact and reduce rotation of a tire mounted adjacent to the C-pillar when a force directs the tire forward. A profile of the rocker panel may be a C shape. The rocker panel may extend from a vehicle A-pillar rearwardly past the C-pillar. The rocker panel may be roll-formed and of an ultra-high strength steel.

Abstract: A vehicle body includes a rocker panel elongated along an axis. The vehicle body includes a pillar fixed to the rocker panel and elongated in a direction transverse to the axis. The rocker panel includes a first flange and a second flange. The first flange and the second flange are on opposite sides of the pillar and spaced from each other in a direction parallel to the axis. The vehicle body includes a reinforcement fixed to the first and second flanges.

Abstract: A method includes forming a short version of a pillar reinforcement and a long version of the pillar reinforcement from a short blank and a long blank, respectively. The long blank includes a first portion and a second portion joined to the first portion. The method includes inserting the short blank into a first section of a cavity of a mold and compressing the short blank in the mold to shape the short blank. The method also includes inserting the long blank into the mold with the first portion positioned in the first section of the mold and compressing the long blank in the mold to shape the long blank. The same mold is used to form both the short blank and the long blank into the short version of a pillar reinforcement and a long version of the pillar reinforcement.

Abstract: An apparatus (10) for helping to protect a vehicle occupant comprises an inflatable vehicle occupant protection device (12), an inflator (14), a cover (16), and a reaction plate (18). The inflator (14) provides inflation fluid to inflate the inflatable device (12). The cover (16) at least partially encloses the inflatable device (12) and the inflator (14). The cover (16) has a front panel (20), which faces a vehicle occupant, and side panels (22), which laterally surround the inflatable device (12). The reaction plate (18) has a base plate portion (56) to which the inflatable device (12), the inflator (14), and the cover (16) are attached. The reaction plate (18) has at least one projection (77, 88) extending from the base plate portion (56). The at least one projection (77, 88) overlies at least a portion of at least one of the side panels (22) of the cover (16) to resist deformation of the at least one side panel laterally away from the inflator (14) as the inflatable device (12) inflates.

Abstract: A cover assembly (10) for covering an inflatable occupant protection device (30) comprises a cover (50). The cover (50) has an inner surface (70) for facing the inflatable occupant protection device and a manually depressible outer surface (72). An electrical switch (110) is actuatable by manual depression of the outer surface (72). A backer plate (120) supports the electrical switch (110) adjacent the inner surface (70). A plurality of openings (122) extend through the backer plate (120). A rib (94) extends from the inner surface (70) of the cover (50) around at least a portion of the periphery of the electrical switch (110). A plurality of stakes (92) extend from the inner surface (70) through the plurality of openings (122) in the backer plate (120). Each of the plurality of stakes (92) has a portion (130) connected with the rib (94) to hold the backer plate (120) on the cover (50).

Abstract: An air bag module (12) includes an air bag (18), a reaction canister (22), and a deployment door (24). The reaction canister (22) has a deployment opening (34). The deployment door (24) includes a door panel (80) which extends across the deployment opening (34). The air bag (18) moves outward through the deployment opening (34) and forcefully against the door panel (80) when inflating. The deployment door (24) further includes a stress riser (98) and a hinge (180). The stress riser (98) is ruptured by the force of the air bag (18) moving against the door panel (80). The hinge (180) supports the door panel (80) for pivotal movement away from the deployment opening (34) when the stress riser (98) has been ruptured. The reaction canister (22) includes a spring clamp (160) which clamps the hinge (180) to the reaction canister (22). The spring clamp (160) dissipates energy by enabling the force of the air bag (18) to move the hinge (180) outward against a bias of the spring clamp (160).