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 frame assemblies and methods of manufacturing the same. The vehicle frame assemblies have rails composed of dissimilar materials.

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: An energy management structure for a vehicle may include a first longitudinal rail, a second longitudinal rail joined to the first longitudinal by at least a cross member and a bumper beam. A bumper panel is further provided wherein the bumper panel may be affixed to the bumper beam. The first deflecting rail includes a first front end and a first rear end. The first front end may be affixed to the bumper panel and the first rear end may be affixed to the cross member proximate to the first longitudinal rail. The second deflecting rail includes a second front end and a second rear end. The second front end may be affixed to the bumper panel and the second rear end may be affixed to the cross member proximate to the second longitudinal rail.

Abstract: The vehicle roof support pillar is provided which includes a pillar inner panel, a pillar outer panel and a unitary closed-section reinforcement member. The unitary closed-section reinforcement member is disposed entirely within a chamber defined by the pillar inner panel and the pillar outer panel. The unitary closed-section reinforcement member includes an upper area and a lower area. The lower area of the unitary close-section reinforcement member has an increasing cross-section below the buckling line. The pillar inner panel includes upper and lower ends. The lower inner end has a greater width relative to the upper inner end. The pillar outer panel also has a progressively increasing width relative to the upper outer end.

Abstract: An energy management structure for a vehicle may include a first longitudinal rail, a second longitudinal rail joined to the first longitudinal by at least a cross member and a bumper beam. A bumper panel is further provided wherein the bumper panel may be affixed to the bumper beam. The first deflecting rail includes a first front end and a first rear end. The first front end may be affixed to the bumper panel and the first rear end may be affixed to the cross member proximate to the first longitudinal rail. The second deflecting rail includes a second front end and a second rear end. The second front end may be affixed to the bumper panel and the second rear end may be affixed to the cross member proximate to the second longitudinal rail.

Abstract: A vehicle structural arrangement 10 is provided which provides improved roof strength and controlled energy absorption when a load is imposed on the roof structure 60. The vehicle structural arrangement includes an inner panel 12, an outer panel 14 and at least one bridge member 16 having a first region 32, a second region 34, and a middle region 36. The middle region 36 may be disposed between and is integral to the first region 32 and the second region 34. The first region 32 of the middle portion abuts the inner panel and the second region 34 of the middle portion abuts the outer panel.

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 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 striker reinforcement plate is configured for installation into the interior of a closed section, hydroformed tubular automotive frame member. The striker reinforcement plate is formed with an enlarged mounting tab at one end and a weld tab at the opposing end. The striker reinforcement plate is inserted through a slot formed into the wall of the tubular frame member, against which the enlarged mounting tab prevents the striker reinforcement plate from falling through the slot, and the weld tab is inserted through a special formed opening to receive the weld tab. The weld tab can then be welded to the exterior surface of the tubular frame member, which combined with the enlarged mounting tab secured against the slot holds the striker reinforcement plate in place for final assembly of the striker. The striker can then be bolted to the reinforcement plate and be positionally adjusted in a conventional manner.

Abstract: A reinforcement member is used to join directly two hydroformed tubular members in an automotive vehicle. The reinforcement member is formed with two spaced triangular plates joined to an orthogonal doubler plate in an integral configuration, providing mating surfaces for connection to orthogonally joined tubular members. The parallel triangular plates improve the joints vertical bending stiffness because the parallel plates provide an increased footprint at the joint. The parallel plates also enhance the lateral bending performance of the joint by locking relative movement of the two tubular members at the joint. The vertical doubler plate increases the thickness of the cross tubular member at the joint to allow a lighter gage tubular member to be utilized. The reinforcement member can be joined by MIG welding techniques on one side or on opposite sides of the cross tubular member for welding to the primary frame member.

Abstract: A striker reinforcement plate is configured for installation into the interior of a closed section, hydroformed tubular automotive frame member. The striker reinforcement plate is formed with an enlarged mounting tab at one end and a weld tab at the opposing end. The striker reinforcement plate is inserted through a slot formed into the wall of the tubular frame member, against which the enlarged mounting tab prevents the striker reinforcement plate from falling through the slot, and the weld tab is inserted through a special formed opening to receive the weld tab. The weld tab can then be welded to the exterior surface of the tubular frame member, which combined with the enlarged mounting tab secured against the slot holds the striker reinforcement plate in place for final assembly of the striker. The striker can then be bolted to the reinforcement plate and be positionally adjusted in a conventional manner.

Abstract: A striker reinforcement plate is configured for installation into the interior of a closed section, hydroformed tubular automotive frame member. The striker reinforcement plate is formed with an enlarged mounting tab at one end and a weld tab at the opposing end. The striker reinforcement plate is inserted through a slot formed into the wall of the tubular frame member, against which the enlarged mounting tab prevents the striker reinforcement plate from falling through the slot, and the weld tab is inserted through a special formed opening to receive the weld tab. The weld tab can then be welded to the exterior surface of the tubular frame member, which combined with the enlarged mounting tab secured against the slot holds the striker reinforcement plate in place for final assembly of the striker. The striker can then be bolted to the reinforcement plate and be positionally adjusted in a conventional manner.

Abstract: A vehicle safety system (10) includes a light source (32). A beam-forming assembly (34) is optically coupled to the light source (32). An object detection sensor (16) detects an object and generates an object detection signal. A controller (18) is coupled to the beam-forming assembly (34) and the object detection sensor (16). The controller (18) adjusts illumination output of the vehicle safety system (10) in response to the object detection signal.

Abstract: A striker reinforcement plate is configured for installation into the interior of a closed section, hydroformed tubular automotive frame member. The striker reinforcement plate is formed with an enlarged mounting tab at one end and a weld tab at the opposing end. The striker reinforcement plate is inserted through a slot formed into the wall of the tubular frame member, against which the enlarged mounting tab prevents the striker reinforcement plate from falling through the slot, and the weld tab is inserted through a special formed opening to receive the weld tab. The weld tab can then be welded to the exterior surface of the tubular frame member, which combined with the enlarged mounting tab secured against the slot holds the striker reinforcement plate in place for final assembly of the striker. The striker can then be bolted to the reinforcement plate and be positionally adjusted in a conventional manner.

Abstract: A vehicle headlight system including a light source, digital beam forming optics optically coupled to the light source, and a memory storing a plurality of light illumination patterns. The memory is electrically coupled to the digital beam forming optics. The digital beam forming optics is adapted to output light from the light source in the form of at least one of the light illumination patterns in response to at least one vehicle operating condition.

Abstract: A vehicle safety system (10) includes a light source (32). A beam-forming assembly (34) is optically coupled to the light source (32). An object detection sensor (16) detects an object and generates an object detection signal. A controller (18) is coupled to the beam-forming assembly (34) and the object detection sensor (16). The controller (18) adjusts illumination output of the vehicle safety system (10) in response to the object detection signal.

Abstract: A vehicle headlight system including a light source, digital beam forming optics optically coupled to the light source, and a memory storing a plurality of light illumination patterns. The memory is electrically coupled to the digital beam forming optics. The digital beam forming optics is adapted to output light from the light source in the form of at least one of the light illumination patterns in response to at least one vehicle operating condition.

Abstract: An interactive method and system for designing a door system for an automotive vehicle without the necessity of building a prototype is disclosed. Initially, a door system design is selected and a set of door system data describing attributes of a door structure, a door opening panel (DOP), mating surfaces of the DOP and the vehicle, vehicle attributes, hardware attributes, and seal system attributes are generated based on the selected design. A door system model is then generated from the door system data, and a design criteria for the door system is selected. Door system performance is then determined using predetermined conditions based upon the door system model by computing and displaying time histories of predefined parameters of the door system, door related hardware, and vehicle passenger compartment.