Abstract: A vehicle door system includes doors with a door module attached to a hinge module, which is attached to the vehicle body. The door module includes a latch mechanism configured to engage a striker pin of the vehicle body, with a pawl that pivots to accommodate a misalignment with the striker pin during a door closing operation, with the latch mechanism shifting following engagement with the striker pin. A door check mechanism includes a permanent magnet and a steel plate. Activation of the permanent magnet shifts the steel plate from a closed position to an open position permitting the hinge module to move from a locked position. An interface between doors includes a primary and secondary seal each having a constant cross section, with filler pieces disposed between the door and the secondary seal along a portion of the interface.

Abstract: A vehicle door system includes a door with a door module and a hinge module. The hinge module is attached to the vehicle body. The door module is attached to the hinge module. The hinge module includes a hinge bracket attached to the vehicle body, and a pair of arms extending from the hinge bracket that can pivot relative to the hinge bracket and a cross brace attached at the ends of the arms. The door module attaches to the cross brace. The door module moves along with the cross brace, which moves along with the arms as they pivot relative to the hinge bracket. The door module includes a latch mechanism at a bottom edge, with the latch mechanism engaging with the vehicle body. A lateral edge of the door may seal against a lateral edge of the second door without a latch interface.

Abstract: A system for modifying the range capability of an electric vehicle includes a vehicle body having a front axle and a rear module secured to the vehicle body. The rear module includes a rear axle and the rear module is detachable from the vehicle body and replaceable with another rear module. The rear modules may include different range extension capabilities. The rear modules may include a battery or a combustion engine that may supplement the standard battery and electric motor of the vehicle. A pair of laterally translatable pins of the rear module may be moveable into and out of engagement with the vehicle body. The rear module may also include vertically extending posts that engage with the vehicle body. The vehicle body may be raised to disengage the posts from the vehicle body.

Abstract: A system for modifying the structure of a unibody vehicle includes a vehicle body having a unibody construction and a first module attached to the vehicle body. The first module is removable from the vehicle body and replaceable with a second module having a different size and/or functionality. A rear portion of the first module may be removed from the first module and attached to the second module. The first module may be a stock cargo module, and the second module may be an aftermarket module. The rear portion may be a stock tail tamp and/or sensor module. The rear portion may be removed before or after removing the first module from the vehicle body, and may be attached to the second module before or after attaching the second module to the vehicle body.

Abstract: A vehicle door system includes a door with a door module and a hinge module. The hinge module is attached to the vehicle body. The door module is attached to the hinge module. The hinge module includes a hinge bracket attached to the vehicle body, and a pair of arms extending from the hinge bracket that can pivot relative to the hinge bracket and a cross brace attached at the ends of the arms. The door module attaches to the cross brace. The door module moves along with the cross brace, which moves along with the arms as they pivot relative to the hinge bracket. The door module includes a latch mechanism at a bottom edge, with the latch mechanism engaging with the vehicle body. A lateral edge of the door may seal against a lateral edge of the second door without a latch interface.

Abstract: A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

Abstract: A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

Abstract: A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

Abstract: The invention provides a method of joining dissimilar materials, such as aluminum to steel, by applying low pressure and heat to minimize distortion of the materials and the heat affected zone. The method includes applying current to a weld element, at least partially melting a portion of the first material with the heated weld element, and passing through the at least partially melted portion of the first material with the weld element. The method further includes contacting the second material with the heated weld element, and melting a portion of the weld element and a portion of the second material in contact with one another to form a weld. The weld element is designed with a head to trap the first material between the head and the second material, and a vent for receiving the at least partially melted first material as the weld element passes through.

Abstract: A gore assembly is provided which is made from at least two metal panels. The metal panels comprise downturned flanges along opposing radial edges. The flanges point away from an A-surface of the gore assembly and face a B-surface. The panels are fastened to each other along the flanges on the radial edges. In addition, the gore assembly includes further metal reinforcement members fastened to the B-surface of the gore assembly to provide additional structural support to the gore assembly. Moreover, local attachment brackets can be fastened to the panel reinforcement members for further structural support and for mounting the gore assembly to a chassis.

Abstract: A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

Abstract: A support system for a trough-shaped solar collector assembly includes a support arm comprising first and second curved rails and an interconnecting web structure. The web structure is secured along first and second opposite edges thereof to first and second web engaging structures, which are provided along facing surfaces of the first and second rails, respectively. Prior to fixedly securing the web structure to the web engaging structure of the first and second curved rails, the location and/or the orientation of the web structure are adjustable for supporting interconnection of the first and second curved rails with different rates of convergence between the first and second curved rails. The support arm further includes a plurality of mirror-attachment brackets coupled to the first rail for attaching the trough-shaped solar collector assembly to the support arm and structure attachment brackets for mounting the support arm to a structure.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: A support system for a trough-shaped solar collector assembly includes a support arm comprising first and second curved rails and an interconnecting web structure. The web structure is secured along first and second opposite edges thereof to first and second web engaging structures, which are provided along facing surfaces of the first and second rails, respectively. Prior to fixedly securing the web structure to the web engaging structure of the first and second curved rails, the location and/or the orientation of the web structure are adjustable for supporting interconnection of the first and second curved rails with different rates of convergence between the first and second curved rails. The support arm further includes a plurality of mirror-attachment brackets coupled to the first rail for attaching the trough-shaped solar collector assembly to the support arm and structure attachment brackets for mounting the support arm to a structure.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: A gore assembly is provided which is made from at least two metal panels. The metal panels comprise downturned flanges along opposing radial edges. The flanges point away from an A-surface of the gore assembly and face a B-surface. The panels are fastened to each other along the flanges on the radial edges. In addition, the gore assembly includes further metal reinforcement members fastened to the B-surface of the gore assembly to provide additional structural support to the gore assembly. Moreover, local attachment brackets can be fastened to the panel reinforcement members for further structural support and for mounting the gore assembly to a chassis.

Abstract: In one aspect of the present invention, a solar energy collection system that includes multiple longitudinally adjacent collectors is described. The collectors are coupled end to end to form a collector row. Each collector includes a reflector, one or more solar receivers and a support structure. There is a space between the support structures of adjacent collectors in the collector row, where the reflectors of the adjacent collectors extend beyond the underlying support structures to form a substantially continuous reflective surface over the space. A coupling device is positioned in the space between the tube assemblies. The coupling device connects and helps to rotate the support structures of the adjacent collectors. Some embodiments relate to various types of coupling devices and collector arrangements.

Abstract: In one aspect of the present invention, a solar energy collection system that includes multiple longitudinally adjacent collectors is described. The collectors are coupled end to end to form a collector row. The collector row extends along a longitudinal axis and is arranged to rotate about a pivot axis to track the sun in at least one dimension. Each collector includes a reflector, one or more solar receivers and a support structure. The support structure includes a tube assembly that underlies the reflector. The tube assemblies of the collector row are arranged end to end along the longitudinal axis. There is a space between the tube assemblies of adjacent collectors in the collector row, where the reflectors of the adjacent collectors extend beyond the underlying tube assemblies to form a substantially continuous reflective surface over the space. A coupling device is positioned in the space between the tube assemblies.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.