Abstract: A ventilation system for a lightweight automobile having a plastic body includes a heating air inlet in fluid communication with fresh air at the engine hood upper cowl of the automobile. The air inlet is rigid plastic and is bonded to the hood to stiffen the hood. The fresh air is directed through the inlet to a heat exchanger shroud within the engine compartment, and the engine exhaust pipe passes through the shroud to heat the air in the shroud. From the shroud, the heated fresh air passes through a bulkhead valve into the passenger compartment, where it can be directed toward the passengers' feet or against the windshield to defrost the windshield. In addition, a rigid plastic fresh air plenum is transversely mounted in the passenger compartment as an instrument panel, and the fresh air plenum stiffens the body. Fresh air from the cowl is directed into the plenum and out of selectively coverable openings in the plenum to cool the passenger compartment.

Abstract: A fiber reinforcing mat is used proximate a through hole in an automotive structural element in order to reinforce the element in the area approximate the through hole. The fiber reinforcing mat is comprised of a warp having a plurality of radially extending loops and a weft which is woven through the loops in a spiral fashion. Since the weft is configured as a spiral, weft material is more dense in the area close to the through hole than in the area distal of the through hole. Consequently, the stiffness of the structural element decreases gradually in radial directions away from the through hole.

Abstract: A fiber reinforcing mat is used proximate a through hole in an automotive structural element in order to reinforce the element in the area approximate the through hole. The fiber reinforcing mat is comprised of a warp having a plurality of radially extending loops and a weft which is woven through the loops in a spiral fashion. Since the weft is configured as a spiral, weft material is more dense in the area close to the through hole than in the area distal of the through hole. Consequently, the stiffness of the structural element decreases gradually in radial directions away from the through hole.

Abstract: A light-weight vehicle door including, in one form, outer and inner plastic panels bonded together with the inner panel molded with upright forward, aft and intermediate frame portions. The forward and aft frame portions providing opposed side walls formed with L-section mirror image window panel supporting rebates including co-planar fore and aft reveal flanges and parallel opposed fence flanges. An inverted U-shaped trim member having vertically extending leg sections with each leg section received in an associated rebate and defining, with a respective fence flange, opposed guide grooves slidably supporting a window panel. A manual window panel regulating mechanism mounted on a lower edge of the window panel having a regulator adapted for cooperative locking engagement with an intermediate frame portion holding the window panel in a partially or fully raised position.

Abstract: A vehicle door assembly including an outer contoured panel, an inner contoured panel, the panels being connected at their side and bottom edges, and a glass and regulator track assembly adapted to being assembled through the adjacent upper edges of the panels into the space between the panels and secured to the inner panel. A majority of the inner trim is molded integrally as the surface of the inner panel, with a separately applied trim element secured to the upper edge portion of the inner panel, and an arm rest secured to the inner panel at a central portion thereof. A side impact beam extends longitudinally between the outer and inner panels, and includes a longitudinally oriented mounting plate at its forward end and a laterally oriented mounting plate at its rear end for mounting on the inner panel.

Abstract: A vehicle door assembly including an outer contoured panel, an inner contoured panel, the panels being connected at their side and bottom edges, and a glass and regulator track assembly adapted to being assembled through the adjacent upper edges of the panels into the space between the panals and secured to the inner panel. A majority of the inner trim is molded integrally as the surface of the inner panel, with a separately applied trim element secured to the upper edge portion of the inner panel, and an arm rest secured to the inner panel at a central portion thereof. A side impact beam extends longitudinally between the outer and inner panels, and includes a longitudinally oriented mounting plate at its forward end and a laterally oriented mounting plate at its rear end for mounting on the inner panel.

Abstract: A lift type tailgate on a passenger van type vehicle body is operated by an electric motor powered actuator with an electronic control circuit utilizing a microprocessor operating under program control to respond to user-initiated opening and closing signals to move the tailgate in the selected direction. In the control circuit, feedback information to the microprocessor indicative of tailgate position is provided by a potentiometer coupled with the actuator motor and the microprocessor is programmed to operate with this information to stop the tailgate at a wide open position, a partially closed position and a fully closed position. Obstruction detection is performed by the microprocessor using an obstruction detection circuit and additionally by monitoring the position signal input from the potentiometer to stop the tailgate on encountering an obstacle.

Abstract: A vehicle door assembly including an outer contoured panel, an inner contoured panel, the panels being connected at their side and bottom edges, and a glass and regulator track assembly adapted to being assembled through the adjacent upper edges of the panels into the space between the panels and secured to the inner panel. A majority of the inner trim is molded integrally as the surface of the inner panel, with a separately applied trim element secured to the upper edge portion of the inner panel, and an arm rest secured to the inner panel at a central portion thereof. A side impact beam extends longitudinally between the outer and inner panels, and includes a longitudinally oriented, mounting plate at its forward end and a laterally oriented mounting plate at its rear end for mounting on the inner panel.

Abstract: A vehicle door assembly including an outer contoured panel, an inner contoured panel, the panels being connected at their side and bottom edges, and a glass and regulator track assembly adapted to being assembled through the adjacent upper edges of the panels into the space between the panels and secured to the inner panel. A majority of the inner trim is molded integrally as the surface of the inner panel, with a separately applied trim element secured to the upper edge portion of the inner panel, and an arm rest secured to the inner panel at a central portion thereof. A side impact beam extends longitudinally between the outer and inner panels, and includes a longitudinally oriented mounting plate at its forward end and a laterally oriented mounting plate at its rear end for mounting on the inner panel.

Abstract: A tailgate is hinged to a passenger van type vehicle body above a substantially vertical rear access opening for swinging movement about a horizontal hinge axis. The tailgate is counterbalanced through its range of movement by spring devices and is opened and closed by a powered actuator mounted on a rear vehicle body pillar. The actuator includes a reversible electric motor driving a worm shaft that drives a worm gear to pivot a crankarm about an axis parallel to the hinge axis. A roller mounted on the crankarm is received in a guide channel that is fixed to the tailgate and extends at right angles to the hinge axis with the pivoting movement of the crankarm thereby translated into swinging tailgate opening and closing movement. The motor is connected with torque sensing circuitry that detects an excessive motor torque demand when the tailgate encounters an obstacle and stops the motor.

Abstract: There is disclosed herein a utility/camper multiple purpose shell integrated with a pick-up truck frame and cab. The shell is adaptable (1) to being fully opened at the rear, (2) to having the roof thereof pivotally raised to permit standing room for a user, (3) to having flexible walls attached to the raised roof suitable for camping therein, and (4) to having the roof thereof lifted off of the front and side walls. The shell components are formed of light weight materials and bonded together.

Abstract: A single arm windshield wiper assembly including a reversible motor, a wiper pivot assembly, and a windshield wiper blade slidably connected to the wiper pivot assembly. A first actuator sub-assembly is operatively connected between the reversible motor and the wiper pivot assembly for reciprocally actuating the wiper blade. A second actuator sub-assembly is operatively connected between the reversible motor and the windshield wiper blade for telescopically moving the wiper blade.

Abstract: A vehicle door assembly including front and rear doors which are latched together, and wherein the usual center pillar is integral with the front door. The rear door can be unlatched from the front door and the rear pillar and opened independent of the front door. Rollers on the rear door slide in a bottom track to roll the door along side the rear of the vehicle.

Abstract: For a vehicle, a unitary vehicle air conditioning and heater assembly with the operative parts of the air conditioning system within a housing enclosure which has various openings therethrough for selective air flow into and out of the enclosure. The vehicle has interior body panel means between the engine compartment and the passenger compartment which form a deep recess which opens into the engine compartment for insertion/ removal of the assembly. The enclosure has various openings therethrough for air flow and the configuration of the recess and housing enclosure are so that the housing enclosure can be readily fitted into and removed from the recess including alignment of the various openings.

Abstract: A vehicle construction comprises a series of modules which can be individually fabricated and assembled to include vehicle operating components before the modules are combined in the final assembly of the vehicle. An underbody module, including a passenger platform preferably integrally constructed with a chassis frame, is a support structure for the remaining modules. A second module comprising a cowl having a windshield frame integrally constructed with a dash panel frame provides structural support for vehicle controls and adjacent modules or body panels. Preferably, the underbody and cowl modules are joined by additional structural supports to form a cage enclosing passenger area of the vehicle. A third module encloses the vehicle area in front of the passenger compartment and a fourth module encloses the area behind the passenger compartment. The modular construction permits assembly by means of a plurality of subassembly lines, each of which pertains to the construction of a single module.

Abstract: A seat tilt mechanism includes a seat frame pivotally secured at its forward end to a floor mounted support. A first toggle link is pivotally secured at a pivot axis eccentrically displaced from the tilt axis for the seat and is in turn pivotally secured to a second link whose other end is pivotally secured to the rear of the seat frame about a support axis. An actuator is pivotally secured for rotation about the support axis together with the second link and preferably, the second toggle link is formed as a portion of the actuator. Moreover, the actuator forms a support leg for supporting the rear end of the seat in the seating position. A latch mechanism retains the seat in its seating position. The latch mechanism is supported by a latch housing which rotates in unison with the support leg so that both members are retracted beneath the seat as the seat is pivoted from its seating position to an access position which permits access to an area behind the seat.

Abstract: An axle drive mechanism comprises an input shaft rotatably mounted in a housing having bearings for supporting the input shaft at opposite ends of the housing. The input shaft includes a pinion gear in meshed engagement with a driven gear coaxially secured about the longitudinal axis of two axle shafts which extend outwardly from the housing. The housing also includes openings at each end of the housing through which the end portions of the input shaft are exposed exteriorly of the housing so that either or both ends of the input shaft can be coupled to a drive line. The axle drive also includes a closure cap adapted to be received in the opening at one end of the housing for enclosing the housing and protecting the unused shaft end.

Abstract: A rail assembly which is especially advantageous for use in constructing the frame and underbody of a motor vehicle comprises an upper channel member, a lower channel member and an intermediate member or web in the form of a corrugated sheet secured between the channel members and whose margins abuttingly engage the peripheral walls of the channels. Each furrow and ridge preferably comprises a planar panel portion. Each planar panel portion is interconnected by a web panel portion which is preferably angled at an acute angle with respect to the transverse axis perpendicular to the longitudinal axis of the rail. Preferably, each planar panel portion has a trapezoidal shape to maximize resistance to bending moments along the longitudinal axis of the rail. The rail design can also be incorporated into other structural elements in a vehicle, i.e. in a pillar arch or a vehicle body, to provide additional rigidity to the vehicle structure.

Abstract: An axle beam for supporting drivetrain and steering components of a motor vehicle comprises a first elongated channel member having a substantially hat-shaped cross section including first and second sidewalls, a bottom wall having a longitudinal edge at one edge of each of the sidewalls, and side flanges extending outwardly from the other edges of the sidewalls. A second elongated member includes surface portions registering with and bonded to the side flanges of the first member. An end plate is secured at each longitudinal end of the beam and is configured to support a wheel spindle support knuckle. Additional steering structure including the steering control assembly can be mounted on sidewalls of the beam. Additional reinforcement can be provided to the axle beam by corrugated web panels inserted within the longitudinal channel as well as by flanged apertures formed in the sidewalls of the first elongated member.