Abstract: A joint structure for a vehicle frame includes a first structural tube, a second structural tube, and a pin. The first structural tube has first and second panels opposing each other. The first structural tube has third and fourth panels opposing each other. The second structural tube extends through the first panel and the second panel. The second structural tube has fifth and six panels opposing each other. The pin is secured to the first structural tube. The pin extends through the third panel, to the fifth panel, through the fifth panel, to the sixth panel, through the sixth panel, to the fourth panel, and through the fourth panel such that the first structural tube, second structural tube, and pin are collectively operable to resist shear and bending forces between the first structural tube and the second structural tube.

Abstract: A vehicle includes a frame, a battery, and blockers. The frame has rails defining a space therebetween. The battery is disposed within the space. The battery is secured to the frame via a floating connection. The battery is configured to store and provide electrical power to propel the vehicle. The blockers protrude inward from the rails and into the space. The blockers are disposed along an edge of the battery. The blockers are spaced-apart from the edge of the battery. The blockers are operable to engage the edge of the battery to limit forward movement of the battery in response to deformation of the frame. The floating connection facilitates limited movement of the battery within the space such that the battery is movable toward the blockers but is prevented from contacting the blockers while the frame is in a non-deformed state.

Abstract: Splayed front horn for vehicle frames are disclosed. An example apparatus disclosed herein includes a first structural member extending along an axial direction of a vehicle, a second structural member coupled to the first structural member, the second structural member splayed relative the first structural member, second structural member including a first section having a first material property, the first section adjacent to the first structural member, and a second section joined to the first section, the second section having a second material property, the first material property different than the second material property.

Abstract: A vehicle includes a hood at a front end, a frunk under the hood, and a cabin. The vehicle includes a cross-beam positioned between the frunk and the cabin, and configured to inhibit protrusion of the frunk into the cabin in a frontal impact. The vehicle also includes a frame and the cross-beam is coupled to the frame. The cross-beam is a unitary member that is coupled to the frame or the cross-beam includes two members separated by a gap and each member is coupled to the frame. The frame includes shock towers for coupling the cross-beam to the frame. The frame can also include a bracket for coupling the cross beam to the frame.

Abstract: This disclosure details systems and methods for supporting and protecting vehicle underbody-mounted battery packs. An exemplary electrified vehicle may include a frame, a battery support structure mounted to the frame, and a battery pack. The battery pack is supported relative to the frame by the battery support structure but is not itself directly coupled to the frame. The battery support structure may be configured to provide an under-frame mounting configuration, cross member positioning, skid plate positioning for battery pack protection, weight optimized sub-components, unique shapes for ground clearances, etc.

Abstract: Barriers for rear frame mounted spare tires are disclosed. An example vehicle disclosed herein includes a frame including a cross member, a spare tire, a skid plate, and a barrier extending between the skid plate and the cross member, the barrier abutting the spare tire, the barrier including a first surface having a first curvature, the first curvature concave relative to a rear of the vehicle.

Abstract: A vehicle includes a hood at a front end, a frunk under the hood, and a cabin. The vehicle includes a cross-beam positioned between the frunk and the cabin, and configured to inhibit protrusion of the frunk into the cabin in a frontal impact. The vehicle also includes a frame and the cross-beam is coupled to the frame. The cross-beam is a unitary member that is coupled to the frame or the cross-beam includes two members separated by a gap and each member is coupled to the frame. The frame includes shock towers for coupling the cross-beam to the frame. The frame can also include a bracket for coupling the cross beam to the frame.

Abstract: Barriers for rear frame mounted spare tires are disclosed. An example vehicle disclosed herein includes a frame including a cross member, a spare tire, a skid plate, and a barrier extending between the skid plate and the cross member, the barrier abutting the spare tire, the barrier including a first surface having a first curvature, the first curvature concave relative to a rear of the vehicle.

Abstract: Splayed front horn for vehicle frames are disclosed. An example apparatus disclosed herein includes a first structural member extending along an axial direction of a vehicle, a second structural member coupled to the first structural member, the second structural member splayed relative the first structural member, second structural member including a first section having a first material property, the first section adjacent to the first structural member, and a second section joined to the first section, the second section having a second material property, the first material property different than the second material property.

Abstract: Splayed front horn for vehicle frames are disclosed. An example apparatus includes a frame of a vehicle having a side rail directed in a longitudinal direction of the vehicle and a splayed front horn coupled to the side rail, the splayed front horn angled outward relative to the longitudinal direction of the vehicle, wherein the splayed front horn includes a first section and a second section, the first and second sections having different physical properties.

Abstract: This disclosure details systems and methods for supporting and protecting vehicle underbody-mounted battery packs. An exemplary electrified vehicle may include a frame, a battery support structure mounted to the frame, and a battery pack. The battery pack is supported relative to the frame by the battery support structure but is not itself directly coupled to the frame. The battery support structure may be configured to provide an under-frame mounting configuration, cross member positioning, skid plate positioning for battery pack protection, weight optimized sub-components, unique shapes for ground clearances, etc.

Abstract: Splayed front horn for vehicle frames are disclosed. An example apparatus includes a frame of a vehicle having a side rail directed in a longitudinal direction of the vehicle and a splayed front horn coupled to the side rail, the splayed front horn angled outward relative to the longitudinal direction of the vehicle, wherein the splayed front horn includes a first section and a second section, the first and second sections having different physical properties.

Abstract: An assembly includes a first frame rail and a second frame rail elongated along a longitudinal axis and spaced from each other along a lateral axis. The assembly includes a crossbeam extending along the lateral axis and fixed under the first frame rail and the second frame rail. The assembly includes a first support member extending transversely from the crossbeam to a first end fixed to the first frame rail. The assembly includes a second support member extending transversely from the crossbeam to a second end fixed to the second frame rail.

Abstract: An assembly includes a first frame rail and a second frame rail elongated along a longitudinal axis and spaced from each other along a lateral axis. The assembly includes a crossbeam extending along the lateral axis and fixed under the first frame rail and the second frame rail. The assembly includes a first support member extending transversely from the crossbeam to a first end fixed to the first frame rail. The assembly includes a second support member extending transversely from the crossbeam to a second end fixed to the second frame rail.

Abstract: A vehicle frame includes two frame rails fixed relative to each other and each having a tubular shape defining an exterior surface and an interior surface, a crush-initiating notch on each exterior surface, and a reinforcement extending along each interior surface and positioned in a vehicle-rearward direction from the notches.

Abstract: A vehicle frame includes two frame rails fixed relative to each other and each having a tubular shape defining an exterior surface and an interior surface, a crush-initiating notch on each exterior surface, and a reinforcement extending along each interior surface and positioned in a vehicle-rearward direction from the notches.

Abstract: A wheel support knuckle and trailing arm assembly that is attached to a toe link of a vehicle suspension system. The trailing arm assembly is formed by a blade member and a reinforcement member. The wheel support knuckle defines an axle bore and includes an integrally formed upper link receptacle and an integrally formed brake caliper track. The toe link is retained on the trailing arm assembly by a clevis formed by a transverse wall formed in the blade member and a parallel transverse wall formed in the reinforcement member. An alternative embodiment discloses a one-piece trailing arm that defines a clevis for connection to the toe link between a transverse wall and a tab that extends parallel to the transverse wall. A method of making cast wheel support knuckle and stamped trailing arm assembly is also disclosed.

Abstract: A wheel support knuckle and trailing arm assembly that is attached to a toe link of a vehicle suspension system. The trailing arm assembly is formed by a blade member and a reinforcement member. The wheel support knuckle defines an axle bore and includes an integrally formed upper link receptacle and an integrally formed brake caliper track. The toe link is retained on the trailing arm assembly by a clevis formed by a transverse wall formed in the blade member and a parallel transverse wall formed in the reinforcement member. An alternative embodiment discloses a one-piece trailing arm that defines a clevis for connection to the toe link between a transverse wall and a tab that extends parallel to the transverse wall. A method of making cast wheel support knuckle and stamped trailing arm assembly is also disclosed.

Abstract: A wheel support knuckle and trailing arm assembly that is attached to a toe link of a vehicle suspension system. The trailing arm assembly is formed by a blade member and a reinforcement member. The wheel support knuckle defines an axle bore and includes an integrally formed upper link receptacle and an integrally formed brake caliper track. The toe link is retained on the trailing arm assembly by a clevis formed by a transverse wall formed in the blade member and a parallel transverse wall formed in the reinforcement member. An alternative embodiment discloses a one-piece trailing arm that defines a clevis for connection to the toe link between a transverse wall and a tab that extends parallel to the transverse wall. A method of making cast wheel support knuckle and stamped trailing arm assembly is also disclosed.

Abstract: A wheel support knuckle and trailing arm assembly that is attached to a toe link of a vehicle suspension system. The trailing arm assembly is formed by a blade member and a reinforcement member. The wheel support knuckle defines an axle bore and includes an integrally formed upper link receptacle and an integrally formed brake caliper track. The toe link is retained on the trailing arm assembly by a clevis formed by a transverse wall formed in the blade member and a parallel transverse wall formed in the reinforcement member. An alternative embodiment discloses a one-piece trailing arm that defines a clevis for connection to the toe link between a transverse wall and a tab that extends parallel to the transverse wall. A method of making cast wheel support knuckle and stamped trailing arm assembly is also disclosed.