Abstract: A vehicle body includes a hollow structural member having an inner surface. The hollow structural member includes a first metal or metal alloy. A structural reinforcement member is positioned in the hollow structural member and includes a stiffener including a second metal or metal alloy different from the first metal or metal alloy. A gap is provided between the stiffener and the inner surface of the structural member. An adhesive is secured to the stiffener. The adhesive is substantially dry to the touch prior to activation and is activatable to expand toward the inner surface to fill at least a portion of the gap. A frame is secured to the stiffener and is positioned between the stiffener and the inner surface of the structural member to maintain the gap prior to expansion of the adhesive. The frame is adapted to insulate the stiffener from the hollow structural member.

Abstract: A multi-material joint includes first and second body members, a staple, a wire ladder, and an adhesive. The first body member includes a first layer of fiber reinforced material which has first upper and lower surfaces. The second body member includes a metal. The staple includes first and second prongs joined by a crown. The first and second prongs are inserted through the first layer such that the crown is positioned adjacent to the first upper surface. The wire ladder is positioned adjacent to the first lower surface and includes first and second rails coupled together by a plurality of rungs. The first and second prongs hook over the respective first and second rungs. The adhesive is positioned between the first and second body members, and covers at least a portion of the crown. Other multi-material joints are also provided, as are methods of making multi-material joints.

Abstract: A joint includes a first body, a second body, and an adhesive. The first body includes a coated portion and an uncoated portion. The second body includes a coated portion and an uncoated portion. The adhesive is positioned on the uncoated portion of each of the first and second bodies. The adhesive is expandable to cover at least a part of the coated portion of each of the first and second bodies. The first body and the second body can be fabricated for dissimilar materials. The adhesive includes insulating properties that can insulate the first body from the second body to inhibit galvanic corrosion. During a method of forming a joint between a first body and a second body, the adhesive can be at least partially cured so as to hold the first body and second body in the proper relative alignment during the formation process.

Abstract: A vehicle body includes a hollow structural member having an inner surface. The hollow structural member includes a first metal or metal alloy. A structural reinforcement member is positioned in the hollow structural member and includes a stiffener including a second metal or metal alloy different from the first metal or metal alloy. A gap is provided between the stiffener and the inner surface of the structural member. An adhesive is secured to the stiffener. The adhesive is substantially dry to the touch prior to activation and is activatable to expand toward the inner surface to fill at least a portion of the gap. A frame is secured to the stiffener and is positioned between the stiffener and the inner surface of the structural member to maintain the gap prior to expansion of the adhesive. The frame is adapted to insulate the stiffener from the hollow structural member.

Abstract: A method of single-sided resistance welding includes providing a first workpiece and a second workpiece. The first workpiece is positioned so that at least a portion of the first workpiece is in contact with at least a portion of the second workpiece. A weld electrode is positioned in contact with the first workpiece, and a ground electrode is positioned in contact with the second workpiece. A determination is made as to whether a gap or other high resistance condition is present between the first workpiece and the second workpiece. If a gap or other high resistance condition is determined to be present between the first workpiece and the second workpiece, the gap or other high resistance condition is reduced, and the first workpiece and the second workpiece are joined through welding.

Abstract: A vehicle sliding door mechanism is arranged to move a door from a door opening provided in a vehicle side body structure from a closed position to an open position. The sliding door mechanism comprises an upper slide rail and a lower slide rail fixed to the vehicle side body structure. An upper slider is associated with the upper rail and is movable along the upper rail, and a lower slider is associated with the lower rail and is movable along the lower rail. An upper link assembly operatively connected to the vehicle door and the upper slider, and a lower link assembly is operatively connected to the vehicle door and the lower slider. At least one link assembly of the upper link assembly and lower link assembly is configured to control a moment of force about a pivot axis while moving the vehicle door between the closed position and the open position.

Abstract: A sliding door mechanism includes an upper slide rail and a lower slide rail fixed to a vehicle side body structure. An upper slider is associated with the upper rail, and a lower slider is associated with the lower rail. An upper link includes a control arm pivotally connected to both the upper slider and a vehicle door. A lower link includes a control arm pivotally connected to both the lower slider and the vehicle door. A control mechanism is operatively associated with a selected one of the upper link and the lower link. The control mechanism includes a first control fixed to the vehicle side body structure and a second control fixed to the control arm of the selected link. Movement of the second control is based on predetermined structural constraints associated with the first control. The control mechanism controls rotation and translation of the upper and lower links.

Abstract: A frame assembly for a vehicle includes a subframe, a collar assembly with a collar member and a mounting pin, and a main frame with a saddle. The main frame has a contact side that faces toward the collar assembly and the saddle is located on the contact side. The subframe is connected to the main frame with a bolt that extends from the subframe and into a bore in the mounting pin. The mounting pin is in contact with the saddle.

Abstract: A sliding door mechanism includes an upper slide rail and a lower slide rail fixed to a vehicle side body structure. An upper slider is associated with the upper rail, and a lower slider is associated with the lower rail. An upper link includes a control arm pivotally connected to both the upper slider and a vehicle door. A lower link includes a control arm pivotally connected to both the lower slider and the vehicle door. A control mechanism is operatively associated with a selected one of the upper link and the lower link. The control mechanism includes a first control fixed to the vehicle side body structure and a second control fixed to the control arm of the selected link. Movement of the second control is based on predetermined structural constraints associated with the first control. The control mechanism controls rotation and translation of the upper and lower links.

Abstract: A vehicle sliding door mechanism is arranged to move a door from a door opening provided in a vehicle side body structure from a closed position to an open position. The sliding door mechanism comprises an upper slide rail and a lower slide rail fixed to the vehicle side body structure. An upper slider is associated with the upper rail and is movable along the upper rail, and a lower slider is associated with the lower rail and is movable along the lower rail. An upper link assembly operatively connected to the vehicle door and the upper slider, and a lower link assembly is operatively connected to the vehicle door and the lower slider. At least one link assembly of the upper link assembly and lower link assembly is configured to control a moment of force about a pivot axis while moving the vehicle door between the closed position and the open position.

Abstract: A frame assembly for a vehicle includes a subframe, a collar assembly with a collar member and a mounting pin, and a main frame with a saddle. The main frame has a contact side that faces toward the collar assembly and the saddle is located on the contact side. The subframe is connected to the main frame with a bolt that extends from the subframe and into a bore in the mounting pin. The mounting pin is in contact with the saddle.

Abstract: A battery mounting system includes a generally planar mounting base having at least one slot. The system further includes a generally planar battery tray containing a battery and having at least one guide extending away from a bottom surface of the battery tray. The battery tray slidably engages the mounting base such that the guide engages the slot, the guide and slot cooperating to control the travel of the battery tray with respect to the mounting base.

Abstract: A battery mounting system includes a generally planar mounting base having at least one slot. The system further includes a generally planar battery tray containing a battery and having at least one guide extending away from a bottom surface of the battery tray. The battery tray slidably engages the mounting base such that the guide engages the slot, the guide and slot cooperating to control the travel of the battery tray with respect to the mounting base.

Abstract: A vehicle body includes a front part having a dashboard. The dashboard has an upper end portion bulged in a rearward direction of the vehicle body. The bulged upper end portion covers an upper portion of a rear reinforcing member with a constant interval provided therebetween. The bulged upper end portion is joined to an upper member and a damper housing. The bulged upper end portion and the rear reinforcing member are combined together to form a closed cross-sectional member directed towards a front pillar and extending from a side frame to the upper member. The rear reinforcing member extends from a lower joining portion located forwardly of a lower part of the dashboard through inside of the bulged upper end portion to the upper member. The rear reinforcing member takes the form of a generally straight line, as viewed in all of front elevation, top plan and side elevation.