Abstract: A rear support structure for the coachwork of a passenger vehicle having closed loop interconnected frame members including a longitudinally extending bottom sill connected at its rearward portion to the forward portion of a rear wheel housing carrier member. The rearward portion of the rear wheel housing carrier member is connected to at least one roof support post which in turn is connected to the roof structure. The connection of the sill to the rear wheel housing carrier member is at a low angle, providing resistance to mechanical fatigue due to flexing and vibration, while at the same time providing a rear passenger door cutout of sufficient size to permit easy entry and egress of rear passengers. The rear wheel housing carrier member has at least two, approximately linear regions, one arcuately flowing into the other for connection of the vehicle's floor structure and two roof support posts of the vehicle bodywork.

Abstract: A light metal casting for use in combination with a metal holder for mounting heavy subassemblies, such as doors or the like, to a light metal frame member of a light metal vehicle body framework, including a first, vertical leg portion having an outward facing surface to which a metal holder is mounted, and a second, inwardly-extending horizontal leg portion connected at an upper end of the first leg portion. The second leg portion is provided with a vertical through-hole oriented transversely to its surface, and, at the edge of the opening which faces the first leg, an upstanding tongue member is formed integrally on the second leg which points away from the first leg and can be bent over the holder.

Abstract: The invention relates to an improved vehicle bodywork for a passenger car with a bearing structure of light-metal extruded sections connected together by cast light metal joining elements. The joining element is disposed on the A pillar assembly and is fitted between a downward sloping forward roof pillar and a vertically oriented forward door pillar and holds an extruded section front end fender brace which extends outwardly therefrom towards the front end of the vehicle. According to the invention, a portion of the outer profile of fender brace conforms to the cross-sectional shape of a surrounding fender panel connected thereto. In this way, the space beneath the fender panel is used to increase the cross section of the fender brace and hence increase rigidity. In a preferred embodiment, the fender brace is L-shaped in cross section having two approximately rectangular hollow-chambers including an outwardly disposed vertical hollow-chamber area and laterally inwardly extending horizontal hollow-chamber.

Abstract: The invention relates to a reinforcement assembly for a sheet metal component in a vehicle bodywork by a second reinforcement piece formed as an extruded light metal section which is additionally secured thereto. The sheet metal component to be reinforced runs straight in a first spatial direction and is curved only in the other two spatial directions. According to the invention, the extruded light metal reinforcement piece is shaped to conformingly fit the curved surfaces of the sheet metal component. The sheet metal component and the reinforcement piece are preferably adhesively secured together. A preferred use of the invention is for reinforcing the sheet metal vehicle floor tub in the high peak stress region of the rear safety belt anchor points. The arrangement of the invention provides an effective reinforcement for heavy loads with good force transmission.

Abstract: In a light-metal vehicle body, a girder assembly joins a first longitudinal girder member located in a forecarriage region of the vehicle body to a second, laterally offset, and generally longitudinally oriented side sill member. The girder assembly includes a pair of open shell-shaped, light-metal castings which form a single, hollow section enclosure when brought together along their mutual open face regions. The concave interior surfaces of the shell-shaped casting are provided with a plurality of spaced integrally formed stiffening rib members. The stiffening ribs are oriented transverse to the curving longitudinal center axis of the girder assembly which curves in conformance with the Z-shape configuration. The stiffening ribs of each shell-shaped castings are arranged in coordinate pairs such that they formed a series of substantially continuous webs along an interior cross section of said girder assembly.

Abstract: A longitudinal bearer joint assembly for joining the abutting ends of two axially aligned, extruded light-metal bearer members of a front end longitudinal bearer assembly in a passenger car bodywork. The two bearer members are designed with different cross sectional profiles and wall thickness dimensions to favorably control deformation of the front end longitudinal bearer assembly. The bearer joint assembly includes a pair of half shell portions which surround and conform to the abutting ends of the two axially-aligned bearer members. The half shell portions include vertical contact surfaces which are mutually offset about a neutral axis in a vertical plane.

Abstract: A bearer joint for a vehicle bodywork, and in particular a longitudinal front bearer joint, and a method for placing a aluminum bearer member on the bearer joint in the vehicle bodywork. The bearer joint comprises a cast aluminum connector for joining together a first forward bearer member and a second rearward bearer member. The connector includes a tubular aluminum recess or socket for receiving the rearward end of the first aluminum bearer member which is fixed thereto by a transverse weld seam at the front receiving edge of the socket. A plurality of offset thickened regions with through holes are provided to the periphery of the socket. To replace a damaged front bearer member, the weld is cut and the damaged front bearer is withdrawn from the socket. A repair kit is provided which includes a replacement front bearer member and a platelike insert sized to fit within an end of the replacement bearer member.

Abstract: An improved door pillar assembly for a passenger car coachwork formed as a substantially vertical extruded light metal hollow-section member and having an outer wall to which longitudinally spaced upper and lower hinge lugs are adjustably secured for swivel connection of a vehicle door. The extruded hollow section member includes a pair of inner transverse ridge members which extend along the longitudinal dimension and divide the hollow interior into three transversely spaced cage sections. Each of the outer cage sections further includes a longitudinal channel formed into the inner surface of the common wall to which the hinge lugs are adjustably secured. An upper and lower pair of slots are provided in the outer wall and are aligned with respect to the channels for receiving the mounting hardware (i.e., bolts) for the hinge lugs whereby the hinge lugs can be selectively positioned within the slots prior to tightening to provide a desired height adjustment.

Abstract: A cast light metal joining element and method of assembly with adjoining extruded light metal hollow section bearer member of a space frame type vehicle body. The joining element or casting includes at least two spaced apart, location points disposed along a surface wall thereof. The location points permit the casting to be held in a corresponding fixture at a desired positionally correct spatial orientation to facilitate the fitting and connection of adjoining frame elements with greater ease, accuracy and smaller tolerances. In one embodiment, the location points include integrally formed conical studs and/or conical depressions. In another embodiment, the location points include through-holes, either straight cylindrical or conically tapered. The studs, depressions and/or holes also served a dual function in providing a positive locking connection to add on components which have corresponding matingly engagable connection surfaces.

Abstract: A center pillar in a motor vehicle constructed of two light metal extruded sections including a first extruded section having one vertical side cut at an acute angled .alpha. over its length and a second extruded section of a uniform cross section. The cut side of the first extruded section is mated to a vertical side edge of the second extruded section in such a way to produce a center pillar having a gradually tapering thickness from bottom to top. The first extruded section includes a bend region at a lower terminal end portion thereof which diverges from the first extruded section and which is cut at an acute angle for smooth transitional connection to a bottom disposed lengthwise connecting member. A plate member is provided for covering the gap created by the divergence of the first extruded section relative the second extruded section.

Abstract: The invention concerns an improved welded joint in a vehicle bodywork for connecting two mutually perpendicular extruded aluminum pieces such as a longitudinal bearer or sill and an upstanding B post. According to the invention, the bottom end of the B post is inserted within an opening in the sill for a positive locking engagement and includes a transverse weld seam which connects the B post to the opening along a first outward facing wall portion of the B post. In addition, a connecting member in the form of a flat plate is placed along the inward facing wall of the B post and is joined at a vertical side edge to the B post by a first weld seam and has a bottom side edge oriented flush with the upper sill surface in the lengthwise direction of the sill and is joined thereto by a second weld seam.

Abstract: A holder for attachment to the underside of a vehicle bodywork for use as a suspension seating. The holder consists of a twin-chambered, extruded aluminum section, which is generally L-shaped in cross-section, and includes a first substantially upright box section which forms the support arm, and a second substantially horizontal box section which forms the support seating surface. The upright support arm is secured, preferably by welding, to a longitudinal support member of the vehicle bodywork. The L-bend region of the support arm includes an internal connecting ridge member which further stiffens the holder in the direction of loading. The bottom seating surface is provided with a relief portion for receiving the protruded end associated with a car jack, a straightening bench, a transport frame, etc. In accordance with the method aspect of the invention, the holders are cut at predetermined section widths from a single extrusion such that both left side and right side holders are made from one extrusion.

Abstract: An improved rear end design for a vehicle body including a first, upper cross member and a second, lower cross member fitted one over the other to form a compound beam. Each cross member is preferably formed as an aluminum extrusion. The upper cross member has the same contour shape as the lower edge of the access door for the trunk. The lower cross member lies below the level of the trunk floor and includes a middle region contour having a curve which matches a corresponding overlying middle region of the upper cross member. Each side end of the lower cross member curves forward under the trunk floor and is joined to a corresponding end of a pair of transversely spaced longitudinal side bearer members or impact-absorption units. The invention provides for a stable rear-end construction, particularly at the joints with the rear impact-absorption units, and also forms a support edge for the trunk-access door. The invention also results in less extensive repairs in the event of a rear collision.

Abstract: A front end bearing structure for the bodywork of a vehicle of the type including a pair of spaced apart left and right side front longitudinal bearer members, each having an upstanding, substantially perpendicular support member for supporting a suspension strut mount at a location above its respective front longitudinal bearer member. Each suspension strut mount is also supported at a front end portion thereof by an additional slanted supporting bearer member which is extended upwardly and rearwardly from a connection point on each front longitudinal bearer member at a point in front of the location of the juncture of the perpendicular support member and front longitudinal bearer member. In this way, each slanted supporting bearer member forms a closed triangular framework with its respective front longitudinal bearer member and perpendicular support member. The angle subtended by the slanted supporting bearer member and the longitudinal bearer member is preferably about 45.degree..

Abstract: A spring strut mounting assembly for fitting on a vehicle body which includes a spring strut having a bearing block mounted at the top end thereof on which elements of the running gear, such as a damper, a spring and link arms, can also be pre-mounted. Support members for attachment to the vehicle body adjacent the location for the suspension strut mounting assembly are provided and have converging free ends which define three boundary points of a free space region for mounting the upper bearing block of the spring strut. The upper bearing block is joined directly to these support members without the need for the conventional spring strut cup which is normally fixed to the vehicle body. In a preferred embodiment of the invention, the support members are aluminum extrusions and the converging free ends are each cut at an oblique angle to provide suitable large contact surfaces for mounting to the corresponding receiving flanges of the upper bearing block of the suspension strut.

Abstract: An improved bearer joint in a vehicle bodywork consisting of extruded light metal bearer members connected together by cast metal joining elements. According to the invention, an end portion of at least one bearer member is received within a concave region of at least one joining element and is connected thereto at two connection points on either side of the coverage region so that the portion of the bearer member between the connection points and overlying the concave region acts as a tension member or steadying strut depending on the direction of the load. In a preferred embodiment, the improved bearer joint is the node connector type joining element located at the middle of the A post where the downwardly and obliquely oriented forward roof post joins the substantially vertically upright forward door post. The invention provides a rigid connection with high expansion and energy absorption capabilities, thereby strengthening an otherwise critical weak point in the vehicle roof structure.

Abstract: A bearer joint for a vehicle bodywork, and in particular a longitudinal front bearer joint, and a process for placing an aluminum bearer on the bearer joint in the vehicle bodywork. The bearer joint comprises a cast aluminum connector for joining together a first forward bearer and a second adjacent bearer. The connector includes a tubular aluminum recess for receiving the rearward end of the first aluminum bearer which is fixed thereto by a transverse weld seam at the front receiving edge of the recess. To replace a damaged front bearer, a ring cut is made to the outer wall of the aluminum recess at a distance from the forward receiving edge corresponding to the zone of thermal influence of the heat affected zone adjacent the weld. A damaged front bearer is then withdrawn from the recess and replaced by a new front bearer which is also welded to the new forward cut edge of the aluminum recess. In this way the front bearer is replaced without compromising the original strength of the bearer joint.

Abstract: The invention comprises a bearing structure for the bodywork of a passenger car wherein front suspension strut mounts are arranged above front longitudinal bearers running down both sides of the vehicle body and are supported by vertical connecting members thereon. A hollow section bearer, acting as a suspension strut bearer, connects the suspension strut mount to a joining element (node) at the middle region of the forward doorpost. According to the invention, the suspension strut bearer is curved such that it will buckle due to a reduction in the radius of curvature in the event of a head-on collision. The buckling action of the suspension strut bearer reduces the force acting on the doorpost, thereby counteracting any possible stressing of the vehicle door. In a further embodiment of the invention, slots and/or notched grooves are provided in the side walls of hollow section bearer to promote the buckling process.

Abstract: A motor vehicle body assembled from a plurality of metal frame profiles held together by node connector elements. Each metal frame profile includes an extruded metal portion and a pre-shaped sheet metal portion attached thereto to form a portion of the outer skin of the completed motor vehicle body. Each pre-shaped sheet metal portion is secured to the extruded metal portion so that it overlaps a part of the outer contour of the extruded metal portion to define an enclosed hollow space. This provides a box-type construction which increases strength and rigidity of the combined frame profile.

Abstract: A vehicle chassis constructed of metal frame elements which are joined together by connecting node elements (connectors). The node elements are configured as upwardly open molded pieces (shells) When assembled, a bottom surface portion of each node element is received in conforming notches disposed adjacent the outwardly facing end surfaces of the joining ends of abutting frame elements in such a manner that no part of the node element forms the inward facing regions of the vehicle frame defining the windscreens and door openings. Each node element is provided with side projections (tangs) which extend beyond the notch portions of the adjoining frame elements to increase surface contact area between the node element and each frame element. A cover plate or the vehicle body skin is provided to cover the upward facing end of the node element.