Abstract: A vehicle body frame includes a longitudinally extending roof side rail. The roof side rail includes an outer panel, an inner panel fixed to the outer panel to define a cavity therebetween, and a reinforcement panel disposed between and fixedly secured to the outer and inner panels. The reinforcement panel separates the cavity into an inner cavity and an outer cavity. The roof rail has a forward end portion and a rearward end portion. An acoustic spray foam control bulkhead is secured within the cavity at the rearward end portion of the roof side rail. The bulkhead includes a first sidewall and a second sidewall spaced from and opposed to the first sidewall. The first and second sidewalls are configured to at least partially confine within the inner cavity between the first and second sidewalls an acoustic spray foam injected into an injection inlet aperture provided on the inner panel.

Abstract: An aerodynamic system for a vehicle having a plurality of heat exchangers can include a front assembly, a pair of front fenders, a hood, a ducting assembly, and a rear assembly. The front assembly can include air inlets. The air inlets can be in fluid communication with at least one of the heat exchangers. The pair of front fenders can include fender outlets in fluid communication with at least one of the heat exchangers. The ducting assembly can be in fluid communication with at least one of the plurality of heat exchangers. The rear assembly can include raised C-pillars, air inlets adjacent the pair of raised C-pillars, a rear spoiler, a rear diffuser, and rear slot assemblies adjacent the rear spoiler.

Abstract: A frame assembly of a vehicle front portion includes a windshield lower beam. A damper mount is disposed on the front portion and deforms when subjected to an impact energy. An A-pillar includes upper and lower pillar portions, the upper pillar portion having a lower end disposed adjacent the windshield lower beam, and the lower pillar portion having an upper end disposed adjacent to the windshield lower beam. A joint includes first and second joint members, the first joint member connecting the windshield lower beam to the lower and upper pillar portions and being connected to the damper mount, the second joint member contained within the first joint member and connected to the windshield lower beam, and upper and lower pillar portions. The joint is configured to resist deformation due to the impact energy such that the damper mount deforms and dissipates the impact energy.

Abstract: A vehicle body frame includes a longitudinally extending roof side rail. The roof side rail includes an outer panel, an inner panel fixed to the outer panel to define a cavity therebetween, and a reinforcement panel disposed between and fixedly secured to the outer and inner panels. The reinforcement panel separates the cavity into an inner cavity and an outer cavity. The roof rail has a forward end portion and a rearward end portion. An acoustic spray foam control bulkhead is secured within the cavity at the rearward end portion of the roof side rail. The bulkhead includes a first sidewall and a second sidewall spaced from and opposed to the first sidewall. The first and second sidewalls are configured to at least partially confine within the inner cavity between the first and second sidewalls an acoustic spray foam injected into an injection inlet aperture provided on the inner panel.

Abstract: A vehicle body frame includes a longitudinally extending roof side rail. The roof side rail includes an outer panel, an inner panel fixed to the outer panel to define a cavity therebetween, and a reinforcement panel disposed between and fixedly secured to the outer and inner panels. The reinforcement panel separates the cavity into an inner cavity and an outer cavity. The roof rail has a forward end portion and a rearward end portion. An acoustic spray foam control bulkhead is secured within the cavity at the rearward end portion of the roof side rail. The bulkhead includes a first sidewall and a second sidewall spaced from and opposed to the first sidewall. The first and second sidewalls are configured to at least partially confine within the inner cavity between the first and second sidewalls an acoustic spray foam injected into an injection inlet aperture provided on the inner panel.

Abstract: A frame assembly of a vehicle front portion includes a windshield lower beam. A damper mount is disposed on the front portion and deforms when subjected to an impact energy. An A-pillar includes upper and lower pillar portions, the upper pillar portion having a lower end disposed adjacent the windshield lower beam, and the lower pillar portion having an upper end disposed adjacent to the windshield lower beam. A joint includes first and second joint members, the first joint member connecting the windshield lower beam to the lower and upper pillar portions and being connected to the damper mount, the second joint member contained within the first joint member and connected to the windshield lower beam, and upper and lower pillar portions. The joint is configured to resist deformation due to the impact energy such that the damper mount deforms and dissipates the impact energy.

Abstract: An air and water management system for a motor vehicle is disclosed. The system includes an air opening allowing air to enter the engine room on a side of the motor vehicle, an engine cover covering at least one component associated with the engine of the motor vehicle, a rib extending from a top side of the engine cover creating a gutter on the engine cover between the rib and a side of the engine room, a water channel formed integrally in the engine cover adjacent and laterally inward of and parallel to the rib and including a drain longitudinally to the rear of the motor vehicle at a rearward portion of the water channel. Air entering the air opening flows over the rib and into the engine room of the motor vehicle. The rib blocks debris that enters the air opening from flowing into the engine room.

Abstract: Some embodiments are directed to a support structure for use with a vehicle, the vehicle having a frame to which the support structure is attached. The support structure can include an elongated pillar defining a hollow portion extending therethrough. The elongated pillar can also define at least two rectangular channels approximately rectangular in cross-section extending through the hollow portion along a direction of elongation of the pillar. The elongated pillar can also define one other channel having a non-parallelogram cross-section extending through the hollow portion along a direction of elongation of the pillar.

Abstract: An air and water management system for a motor vehicle is disclosed. The system includes an air opening allowing air to enter the engine room on a side of the motor vehicle, an engine cover covering at least one component associated with the engine of the motor vehicle, a rib extending from a top side of the engine cover creating a gutter on the engine cover between the rib and a side of the engine room, a water channel formed integrally in the engine cover adjacent and laterally inward of and parallel to the rib and including a drain longitudinally to the rear of the motor vehicle at a rearward portion of the water channel. Air entering the air opening flows over the rib and into the engine room of the motor vehicle. The rib blocks debris that enters the air opening from flowing into the engine room.

Abstract: An acoustic spray foam control system and method are provided for a sunroof drain tube area in a vehicle. The system and method include an acoustic spray foam control baffle that is mounted within the sunroof drain tube area of the vehicle and a sunroof drain tube that is installed in the sunroof drain tube area by passing through the acoustic spray foam control baffle. The system and method also include acoustic spray foam that is injected into the sunroof drain tube area with flow of the acoustic spray foam controlled by the acoustic spray foam control baffle.