Abstract: A motor vehicle frame includes a pair of longitudinal frame members. A cross member is provided to maintain the frame members in a spaced apart condition. The cross member has a first end configured to mount to a first one of the longitudinal frame members and a second end configured to engage a steering gear housing. The second end sandwiches steering gear housing as the second end is fastened to a second one of the frame members.

Abstract: A cross member for a motor vehicle includes an elongated, non-cast center structure and first and second castings. The center structure is formed as a one-piece, unitary structure and has a first end, a mid portion, and a second end. The first casting is rigidly connected to the first end of the center structure and the second casting is rigidly connected to the second end of the center structure. Each of the castings is configured and arranged to be attached to a respective motor vehicle element.

Abstract: A bumper system for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes a bumper beam and an energy absorber. The bumper beam includes an upper beam wall, a lower beam wall, and a central beam wall between the upper and lower beam walls. The energy absorber is mounted to the bumper beam and includes an upper absorber wall, a lower absorber wall, and a central absorber wall between the upper and lower absorber walls. The energy absorber has a height that is greater than a height of the bumper beam such that the upper absorber wall is spaced upwardly above the upper beam wall and the lower absorber wall is spaced downwardly below the lower beam wall.

Abstract: A continuous, hydroformed tubular member includes a horizontal member having a first end and a second end. A first vertical member has a first lower end coupled to the first end of the horizontal member. The first vertical member also has a first upper pillar-free end to form a first pillar configured to form a terminal end of an upwardly-open rear bed of a motor vehicle. A second vertical member has a second lower end coupled to the second end of the horizontal member. The second vertical member also has a second upper pillar-free end to form a second pillar configured to form the terminal end of the upwardly-open rear bed of a motor vehicle. The horizontal member, the first vertical member, and the second vertical member together form a one-piece, unitary U-shaped member.

Abstract: A space frame for a motor vehicle having a pair of laterally spaced, longitudinally extending side rail structures, a pair of forward-most upright structures each being connected to a respective side rail structure, thereby forming a pair of A pillars, a pair of roof rail structures, a forward end of each roof rail structure being connected to an upper end of an associated A pillar, and a rearward ring assembly connected at upper portions thereof with the roof rail structures and at bottom portions thereof with the side rail structures. The rearward ring assembly having (a) a tubular hydroformed inverted U-shaped upper member having a cross portion and a pair of leg portions extending downwardly from opposite ends of the cross portion, (b) a pair of tubular hydroformed side members, and (c) a cross structure rigidly connected in ring-forming relation between the second ends of the side members.

Abstract: A bumper beam includes a first portion of a first material and a second portion of a second material. The first material has different material properties than the second material. For example, the first material may have a generally higher tensile or yield strength than the second material. In one embodiment, the first material comprises martensitic steel, while the second material comprises a dual-phase, multiphase, complex-phase or TRIP steel. In addition, the first material may have a different thickness than the second material. The bumper beam provides an improved strength to weight ratio than conventional bumper beams. This abstract is provided to comply with the rules requiring an abstract that allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope of the claims. 37 CFR 1.72(b).

Abstract: A bumper beam includes a first portion of a first material and a second portion of a second material. The first material has different material properties than the second material. For example, the first material may have a generally higher tensile or yield strength than the second material. In one embodiment, the first material comprises martensitic steel, while the second material comprises a dual-phase, multiphase, complex-phase or TRIP steel. In addition, the first material may have a different thickness than the second material. The bumper beam provides an improved strength to weight ratio than conventional bumper beams. This abstract is provided to comply with the rules requiring an abstract that allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope of the claims.

Abstract: A module for a frame for a motor vehicle with a pair of laterally spaced, longitudinally extending central side rail structures. The module including a pair of tubular hydroformed side rail members and a laterally extending connecting structure connected between the pair of side rail members to secure the pair of side rail members in laterally spaced, fixed relation to one another. Each first portion of the pair of side rail members extending longitudinally and each second portion of the pair of side rail members extending laterally relative to the respective first portion and each second portion having an end being constructed and arranged to form a joint with a portion of a respective central side rail structure such that the end of each of the pair of side rail members extends generally laterally through a side of the respective central side rail structure.

Abstract: A space frame for an motor vehicle having hydroformed upper and lower longitudinal members and hydroformed cross-members. Each upper longitudinal member is connected to a corresponding lower longitudinal member in the front and at the rear of the frame by members formed of stamped sheet metal. The stamped components can form part of the front and rear wheel wells. The use of stamped members to connect hydroformed members can permit the use of hydroformed members in motor vehicles with minimum amounts of space for frame members.

Abstract: A method of forming a structural member includes hydroforming the blank to form a hydroformed member and finishing the hydroformed member by positioning the wall of the hydroformed member between a die surface and an electromagnetic discharging element having a non-circular cross-section, and actuating the electromagnetic discharging element so that the metallic wall of the hydroformed member presses against the die surface.

Abstract: An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.

Abstract: A welding assembly including a welding gun for providing spaced welds on opposite sides of members being welded. The welding gun includes two welding tips so that both welds can be formed without moving the gun or the members relative to each other. Preferably one weld tip is connected to a force applying mechanism such as a hydraulic cylinder to clamp the members together and improve the connection between the weld tips and the members. The weld gun can be used for making one or two welds while in the engaged position around the members being welded. Also, one of the weld tips can be replaced with a support that merely provides the force applying function.

Abstract: A welding material is constructed and arranged to be positioned in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material includes at least one welding material member constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the exterior surface of the first weldable member and then positioned between the exterior surfaces of the first and second weldable members to be electrically conductively disposed therebetween.

Abstract: A space frame for a motor vehicle having a pair of laterally spaced, longitudinally extending side rail structures, a pair of forward-most upright structures each being connected to a respective side rail structure, thereby forming a pair of A pillars, a pair of roof rail structures, a forward end of each roof rail structure being connected to an upper end of an associated A pillar, and a rearward ring assembly connected at upper portions thereof with the roof rail structures and at bottom portions thereof with the side rail structures. The rearward ring assembly having (a) a tubular hydroformed inverted U-shaped upper member having a cross portion and a pair of leg portions extending downwardly from opposite ends of the cross portion, (b) a pair of tubular hydroformed side members, and (c) a cross structure rigidly connected in ring-forming relation between the second ends of the side members.

Abstract: An apparatus and method for welding members that are formed at least in part of aluminum. A welding assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. A welding method includes alternatively attaching the welding material members to a weldable member without a carrier sheet, by a welding process.

Abstract: A method of forming a structural member includes hydroforming the blank to form a hydroformed member and finishing the hydroformed member by positioning the wall of the hydroformed member between a die surface and an electromagnetic discharging element having a non-circular cross-section, and actuating the electromagnetic discharging element so that the metallic wall of the hydroformed member presses against the die surface.

Abstract: A door seal interface structure for a motor vehicle space frame includes a longitudinally extending hydroformed tubular rail portion, a hydroformed tubular pillar portion connected at a joint to the rail portion and a transition structure. The rail portion and the pillar portion provide respective surface portions constructed and arranged to sealingly engage a door seal to seal a peripheral portion of a closed vehicle door. The pillar and rail surface portions are angularly related to one another in the vicinity of the joint. The transition structure is mounted on the rail portion and the pillar portion in the vicinity of the joint and provides a transition surface that provides a transition between the pillar and rail surfaces of the pillar and rail portions, the transition surface portion being constructed and arranged to sealingly engage a portion of the door seal to seal the closed vehicle door and thereby provide a door seal-engagable surface in the vicinity of the joint.

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of the first and second weldable members to be welded, each welding material member is electrically conductively disposed therebetween.

Abstract: A welding material in positioned in electrically conductive relation between exterior surface portions of first and second weldable members, such as hydroformed tubes, at a location where the first and second weldable members are to be joined. A welding device comprises first and second electrodes or conductive ends that extend along substantially the entire extent of first sides of the first and second weldable members, respectively. The first and second conductive ends include first and second concave recesses, which nest with the first and second weldable members, respectively. Electrical current is applied across the first and second weldable members by the nesting first and second conductive ends such that the applied current melts the welding material and thereby welds the exterior surface portions to one another. The welding device can be mounted on a robotic mechanism, which can move the welding device between first and second welding positions.

Abstract: A vehicle space frame for constructing a motor vehicle includes a body module and a front module. The body module includes a pair of laterally spaced, longitudinally extending main side rail structures and a pair of rearward-most upright structures each being connected to a respective main side rail structure and extending upwardly therefrom to form a pair of rearward-most pillars thereon. The body module further includes a pair of hydroformed upper longitudinal members each being defined by an outwardly deformed tubular metallic wall fixed in a predetermined irregular exterior surface configuration and each including a pillar-forming portion and a longitudinally extending portion.