Abstract: A battery mounting structure includes a shear plate and a plurality of separate reinforcement plates. The shear plate extends in a longitudinal direction of the vehicle and includes a first thickness. The reinforcement plates are configured to be disposed between the shear plate and the battery housing assembly and are mounted on an upper surface of the shear plate. The reinforcement plates are spaced apart from each other and include a second thickness. The second thickness is greater than the first thickness.

Abstract: A mounting structure for mounting a battery tray to a frame of a vehicle includes a shear plate and a plurality of discrete mounting blocks. The shear plate extends in a longitudinal direction of the vehicle. The plurality of discrete mounting blocks are mounted onto the shear plate between the shear plate and a bottom cover of the battery tray. Each mounting block of the plurality of discrete mounting blocks includes a plurality of walls that define one or more cavities. The discrete mounting blocks includes a set of first mounting blocks located proximate a first side of the shear plate and a set of second mounting blocks located proximate a second side of the shear plate that is opposite the first side of the shear plate.

Abstract: An energy absorbing structure connects a first structure of a vehicle to an adjacent second structure of the vehicle. The energy absorbing structure includes support beams and lattice arrays. Each support beam is located at a respective corner of the energy absorbing structure and extend in a longitudinal direction of the vehicle. The support beams connect the first structure to the second structure. The lattice arrays are located at respective sides of the energy absorbing structure and form a periphery of the energy absorbing structure. Each lattice array connects adjacent support beams to each other.

Abstract: A vehicle includes a vehicle frame having a first frame rail and a second frame rail spaced from each other. The vehicle frame includes a cross-member extending from the first frame rail to the second frame rail. A battery enclosure extends from the first frame rail to the second frame rail. The battery enclosure includes a first side member and a second side member. The first side member is connected to and deformable relative to the first frame rail. The second side member is connected to and deformable relative to the second frame rail. The battery enclosure includes a reinforcement connected to the first side member, the second side member, and the cross-member.

Abstract: A vehicle includes a vehicle frame having first frame rail and a second frame rail spaced from each other. The vehicle frame includes a cross-member extending from the first frame rail to the second frame rail. A battery enclosure extends from the first frame rail to the second frame rail. The battery enclosure includes a first side member and a second side member. The first side member is connected to and deformable relative to the first frame rail. The second side member is connected to and deformable relative to the second frame rail. The battery enclosure includes a reinforcement connected to the first side member, the second side member, and the cross-member.

Abstract: An expanded laminate and method of forming an expanded laminate are disclosed. In at least one embodiment, the method includes selectively applying a relatively high temperature-resistant material to a surface of a first metal sheet to form a covered portion and an uncovered portion and diffusion bonding the first metal sheet to a second metal sheet at the uncovered portion to form a bonded region and an unbonded region. Pressurized gas may be introduced between the first and second metal sheets to expand the first and second metal sheets in the unbonded region. The metal sheets may be aluminum sheets. The sheets may be positioned in a die having a plurality of cavities such that when the pressurized gas is introduced the sheets expand into the cavities. The diffusion bonding may be performed by applying pressure, for example, using rollers.

Abstract: A system includes a roof and an airbag supported by the roof. The airbag is inflatable away from the roof to an inflated position. The airbag includes an apex adjacent to the roof. The airbag includes a first leg inflatable away from the apex to an end, and a second leg inflatable away from the apex to an end spaced from the end of the first leg. The airbag includes a bottom portion spaced from the apex and inflatable to the inflated position. The bottom portion extends from the end of the first leg to the end of the second leg.

Abstract: A cage assembly is provided to protect a battery pack in a vehicle. The cage assembly includes a top sub-assembly and a bottom sub-assembly that are secured together to protect the battery pack. U-shaped frames and base frames are connected together by tubular members. A method of making a cage for a battery pack of a vehicle is provided. The method may include assembling a first plurality of spaced tubes and a plurality of spaced inverted U-shaped frames to from a first sub-assembly. The method may also include assembling a second plurality of spaced tubes and a plurality of spaced frames to form a second sub-assembly. The first sub-assembly and the second sub-assembly may be assembled together to enclose the battery pack.

Abstract: A system includes a roof and an airbag supported by the roof. The airbag is inflatable away from the roof to an inflated position. The airbag includes an apex adjacent to the roof. The airbag includes a first leg inflatable away from the apex to an end, and a second leg inflatable away from the apex to an end spaced from the end of the first leg. The airbag includes a bottom portion spaced from the apex and inflatable to the inflated position. The bottom portion extends from the end of the first leg to the end of the second leg.

Abstract: A front end structure is disclosed for a vehicle to enhance vehicle compatibility performance. The front end structure includes a bumper disposed behind a front fascia panel. Crush cans are attached between the bumper and a frame rail. A shield is attached to the bumper that extends above the bumper and below the bumper to spread deformation caused by the crush cans and bumper of a deformable barrier in a collision to areas above and below the bumper.

Abstract: A front end structure is disclosed for a vehicle to enhance vehicle compatibility performance. The front end structure includes a bumper disposed behind a front fascia panel. Crush cans are attached between the bumper and a frame rail. A shield is attached to the bumper that extends above the bumper and below the bumper to spread deformation caused by the crush cans and bumper of a deformable barrier in a collision to areas above and below the bumper.

Abstract: A roof bow for a vehicle is provided that has a “bow-tie” shape including a central portion flanked by two triangular portions. The triangular portions are joined to right and left roof brackets that are, in turn, joined to right and left roof rails. The bow-tie roof bow may be assembled from extruded tubular parts. The bow-tie roof bow may be assembled in a clamshell structure including an upper shell and a lower shell that are joined together by welding. The roof bow may be formed in one piece as a sheet metal stamping having side portions that are wider than the central portion.

Abstract: A roof bow for a vehicle is provided that has a “bow-tie” shape including a central portion flanked by two triangular portions. The triangular portions are joined to right and left roof brackets that are, in turn, joined to right and left roof rails. The bow-tie roof bow may be assembled from extruded tubular parts. The bow-tie roof bow may be assembled in a clamshell structure including an upper shell and a lower shell that are joined together by welding. The roof bow may be formed in one piece as a sheet metal stamping having side portions that are wider than the central portion.

Abstract: A hydro-formed body side rail is assembled by a bracket to a front header. The front header is an extruded cross-car structural support that is joined to the body side rail by a framed joint. A gap is defined between the body side outer panel and the hydro-formed side rail relative to a lateral end of a front header. Side impact test loads are applied initially to the body side rail and compress the bracket. Compression of the bracket closes the gap and the impact loads are applied to the cross-car structural support.

Abstract: The present invention in one or more embodiments provides a vehicle roof structure which includes a cast node including a pillar portion for receiving a pillar and a roof-rail portion for receiving a roof rail, the roof-rail portion having first and second ends, which may have a closed first cross-section and a closed second cross-section, respectively. The closed first cross-section may be different from the closed second cross-section such that the first and second ends are to receive two individual roof rails of different dimensions. The closed first cross-section may be larger in opening dimension than the closed second cross-section, when the first end is positioned closer to a front of the vehicle than the second end.

Abstract: A roof rail assembly for a vehicle that includes a body side outer and an interior trim piece connected to the body side outer. The body side outer and the interior trim piece define a cavity. A roof rail is positioned within the cavity, and a side curtain air bag is positioned below the roof rail. The interior trim piece is assembled about a lower surface of the roof rail in a spaced relationship relative to the curtain air bag to increase visibility around the roof rail assembly.

Abstract: A cage assembly is provided to protect a battery pack in a vehicle. The cage assembly includes a top sub-assembly and a bottom sub-assembly that are secured together to protect the battery pack. U-shaped frames and base frames are connected together by tubular members. A method of making a cage for a battery pack of a vehicle is provided. The method may include assembling a first plurality of spaced tubes and a plurality of spaced inverted U-shaped frames to from a first sub-assembly. The method may also include assembling a second plurality of spaced tubes and a plurality of spaced frames to form a second sub-assembly. The first sub-assembly and the second sub-assembly may be assembled together to enclose the battery pack.

Abstract: An expanded laminate and method of forming an expanded laminate are disclosed. In at least one embodiment, the method includes selectively applying a relatively high temperature-resistant material to a surface of a first metal sheet to form a covered portion and an uncovered portion and diffusion bonding the first metal sheet to a second metal sheet at the uncovered portion to form a bonded region and an unbonded region. Pressurized gas may be introduced between the first and second metal sheets to expand the first and second metal sheets in the unbonded region. The metal sheets may be aluminum sheets. The sheets may be positioned in a die having a plurality of cavities such that when the pressurized gas is introduced the sheets expand into the cavities. The diffusion bonding may be performed by applying pressure, for example, using rollers.

Abstract: A beam sub-assembly for a vehicle includes a beam member and at least one carbon-fiber prepreg bonded to a first portion of an exterior surface of the beam member so as to cover an entire length of the beam member along the first portion.

Abstract: A cage assembly is provided to protect a battery pack in a vehicle. The cage assembly includes a top sub-assembly and a bottom sub-assembly that are secured together to protect the battery pack. U-shaped frames and base frames are connected together by tubular members.