Abstract: The present invention in one embodiment provides a door structure that includes a door shell having an exterior panel and an interior panel; an anti-intrusion beam positioned between the interior panel and the exterior panel of the door shell; a hinge end casting positioned at a first end of the door shell connected to a first end of the anti-intrusion beam through the interior panel; a lock end casting positioned at a second end of the door shell connected to a second end of the anti-intrusion beam through the interior panel; and a door hardware module mounted to the exterior face of the interior panel.

Abstract: A brake system including a suspension component housing at least one actuation piston to reversibly extend a brake pad; and a wheel that is in rotational engagement to the suspension component, the wheel having a rim portion with an interior surface that is contacted by the brake pad of at least one actuation piston when in an extended position.

Abstract: A braking system comprising a friction surface disposed along an inner surface of a wheel; and a suspension component housing at least one extendable brake pad, wherein said brake pad engages said friction surface when in an extended position.

Abstract: A lower control arm for a motor vehicle suspension includes a first member in the form of an elongated hollow member and a second member attached to the first member. The second member has a solid cross section. The second member has a first end attached to the first member and a second end configured for connection to the motor vehicle body. The first member may have at least one opening extending transversely therethrough for connecting the first member to the motor vehicle suspension system.

Abstract: A reinforcement for a closure panel including an outer panel and an inner panel includes a palm area reinforcement for attachment to the outer panel and a latch area reinforcement for attachment to the inner panel, the latch area reinforcement being disposed on a depression in the reinforcement which is integral with the palm area reinforcement.

Abstract: An antenna is formed from one of the structural components of a vehicle with which the antenna is used. A preferred antenna is formed as a portion of a roof side rail of a vehicle.

Abstract: A vehicle tailgate extension apparatus and method of using the same. The tailgate extension apparatus generally includes a U-frame member, a plurality of hinge elements, and a plurality of side braces. The U-frame member may be locked into a plurality of operative positions optionally including a backstop position, an extension position, and a step position. The extension apparatus is stored within the interior of the tailgate until needed, and the extension may be pulled out of the tailgate via a plurality of storage channels. The side braces directly connect the U-frame member to the vehicle tailgate and may be stored within the arms of the U-frame when the extension apparatus is stowed in the tailgate.

Abstract: A sliding door for vehicles including a space frame formed from a U-shaped extruded aluminum tube and a crossbeam to which inner and outer aluminum door panels are attached. Hardware for operation of the door is mounted on the exposed inside surface of the door. The overall weight of the door is about 20 pounds and the door is about 35 mm thick. A movable window assembly for such a door and a method of making are also disclosed.

Abstract: The liftgate for a motor vehicle includes a frame member, an inner panel, and an outer panel. The frame member is a U-shaped member formed by a cross member and a pair of spaced apart legs extending from the cross member. The inner panel is connected to the legs and extends part way up the legs of the frame member. The outer panel is connected to the inner panel and is positioned opposite the legs and an inner side of the inner panel. The outer panel also extends part way up the legs of the frame member. The frame member defines a window opening with the inner panel and the outer panel. The frame member forms the entire upper portion of the liftgate.

Abstract: The bumper system is used on a motor vehicle and generally includes a bumper beam and an energy-absorbing bracket connected to the bumper beam. The bracket includes a hollow energy-absorbing body having a first end and a second end. The bracket body may be saddle-shaped between the first and second ends. The bracket body deforms during a collision involving the motor vehicle. In another embodiment, the bracket body may have a first cross sectional shape at the first end that transitions to a second cross sectional shape at the second end. The second shape may be different from the first shape, or be similar to the first shape, but be, for example, rotated about 90° from the first shape. The first shape may be elongated along a first axis and the second shape elongated along a second axis rotated about 900 from the first axis.

Abstract: A vehicle tailgate extension apparatus and method of using the same. The tailgate extension apparatus generally comprises a U-frame member, a plurality of hinge elements, and a plurality of side braces. The U-frame member may be locked into a plurality of operative positions optionally including a backstop position, an extension position, and a step position. The extension apparatus is stored within the interior of the tailgate until needed, and the extension may be pulled out of the tailgate via a plurality of storage channels. The side braces directly connect the U-frame member to the vehicle tailgate and may be stored within the arms of the U-frame when the extension apparatus is stowed in the tailgate.

Abstract: A lower control arm for a motor vehicle suspension includes a first member in the form of an elongated hollow member and a second member attached to the first member. The second member has a solid cross section. The second member has a first end attached to the first member and a second end configured for connection to the motor vehicle body. The first member may have at least one opening extending transversely therethrough for connecting the first member to the motor vehicle suspension system.

Abstract: A lightweight tailgate assembly for pickup trucks and other motor vehicles includes several metal panels that are made from a single metal sheet and a plastic reinforcing module between inner and outer metal panels. The side panels of the tailgate are formed as part of the plastic reinforcing module. A preferred assembly may also include a hinge device for connection with a truck body and a latch mechanism for locking the assembly between opposed rear corner posts in a truck body. The hinge device may be integrally molded into the plastic reinforcing module. A particularly preferred tailgate assembly made with AA 6022 aluminum alloy sheet and a reinforcing module containing polymer and glass fibers may weigh less than half as much as a conventional steel truck tailgate. Metal cover plates can be used to obscure visibility of the plastic side panels from the exterior.

Abstract: A vehicle trailer hitch including an aluminum tubular U-shaped strut and a cast aluminum receiver mounted thereto which engages with an electrical connector. Ends of the strut are flatted to form integral planar mounting flanges for mounting the hitch to a vehicle.

Abstract: A universal joint yoke having a tubular body and a pair of ears projecting generally axially therefrom is provided. The ears-have an inner surface, an outer surface and an ear connecting surface. The ear connecting surface has a pair of lower portions, a pair of transition portions and an upper portion. The lower portions are oriented such that a generally straight line drawn in the tubular body connecting surface plane goes through (i) a point at the junction of the ear outer surface and the ear connecting surface; (ii) a point at the junction of the ear inner surface and the ear connecting surface; and (iii) a point on the axis of the tubular body. The upper portion is oriented such that a generally straight line drawn between (i) a point on the junction of the ear outer surface and the ear connecting surface and (ii) a point at the junction of the ear inner surface and the ear connecting surface is generally parallel to the common axis. The universal joint yoke includes a generally concave endcap.

Abstract: A scissor jack having four aluminum arms of U-shaped cross section which are substantially identical and which may include a hollow aluminum lead screw. The threaded nut through which the lead screw is mounted may be made of glass fiber reinforced plastic as may the saddle which is adapted to engage the undercarriage of a vehicle.

Abstract: A panel consisting of a first metallic sheet and a second plastic rigidifying sheet, such as a synthetic resin. The plastic sheet is adhered to the metallic sheet and is integrally molded into a plurality of irregular inverted cup-shaped elements. The cup-shaped elements are arranged to provide the sheet with the desired strength and stiffness and to accommodate components over which it is disposed.