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 vehicle roof frame includes an adhering structure having an adhesive carrier and an expanding structural adhesive coupled to at least a portion of an outer surface of the adhesive carrier. The expanding structural adhesive includes an installation state and a structural state, and the structural state has a larger volume than the installation state. The vehicle roof frame also includes a plurality of vehicle frame members that cooperate to form a frame joint and a joint cavity defined within the frame joint. The adhering structure is disposed within the joint cavity and the adhesive carrier and the expanding structural adhesive in the structural state substantially occupies the joint cavity and fixably couples the plurality of framing members such that the frame joint is free of supplemental mechanical connections proximate the joint cavity.

Abstract: A vehicular system is provided with a substantially hollow member having a long axis, a short axis, and an outer surface substantially parallel to the long axis. The outer surface includes a plurality of notched elements configured to reduce strain from bending the member in the direction of the short axis, e.g., by a stretch bending process. The hollow member may also include an outer surface that is curved substantially in the direction of the short axis. A method of making the vehicular assembly includes the steps: providing a substantially hollow member having a long axis, a short axis, and an outer surface substantially parallel to the long axis; cutting a plurality of notched elements into the outer surface; and bending the member such that the portion of the outer surface in proximity to the notched elements is in tension and curved in the short axis direction.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A vehicular system is provided with a substantially hollow member having a long axis, a short axis, and an outer surface substantially parallel to the long axis. The outer surface includes a plurality of notched elements configured to reduce strain from bending the member in the direction of the short axis, e.g., by a stretch bending process. The hollow member may also include an outer surface that is curved substantially in the direction of the short axis. A method of making the vehicular assembly includes the steps: providing a substantially hollow member having a long axis, a short axis, and an outer surface substantially parallel to the long axis; cutting a plurality of notched elements into the outer surface; and bending the member such that the portion of the outer surface in proximity to the notched elements is in tension and curved in the short axis direction.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A bracket has an elongate portion of a predetermined length. The elongate portion terminates in a clamp end that includes a downward sloping portion connected to a curved contact portion. The curved contact portion is configured to contact a tunable bead of a sheet metal portion of a vehicle body structure such as a pillar. The sheet metal portion comprises a generally planar mating surface, an opening in the depression, and a bead rising from the mating surface, wherein the height of the bead is configured for a top surface of the bead to contact a bottom portion of a clamp when the clamp is in a secured position.

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 panel incorporated into a pillar of a vehicle body includes a base portion defining an opening, and a flange extending from an edge of the opening such that a portion of the flange forms an acute angle with the base portion.

Abstract: A panel incorporated into a pillar of a vehicle body includes a base portion defining an opening, and a flange extending from an edge of the opening such that a portion of the flange forms an acute angle with the base portion.