Abstract: A motor compartment structure for a vehicle includes an intermediate joint welded to a forward region of a cab of the vehicle. Also included is an upper motor compartment rail having a forward end and a rearward end, the rearward end mechanically fastened to the intermediate joint.

Abstract: A method of manufacturing a structural support member for a vehicle includes forming a first portion, forming a second portion, and connecting the first portion and the second portion together. The first portion and the second portion may be formed from one of an aluminum material, a magnesium material, a cold-formable steel material, a glass fiber composite material, or a plastic material. The first portion and the second portion are connected together such that the second portion is disposed in a tensile loading condition in response to an impact load applied to the first portion. A laminate layer is attached to the second portion. The laminate layer includes an ultra high strength material having a yield strength equal to or greater than five hundred fifty (550) MPa. The laminate layer may include, for example, an iron based glassy metal foil or an iron based glassy metal foil fabric.

Abstract: A flow drill screw includes a shank that extends along a rotation axis. The shank includes a flow drill portion and a thread portion. A head is attached to the shank at a second axial end of the shank, adjacent the thread portion. An attachment portion extends from the head and away from the thread portion, along the rotation axis. The attachment portion may include a T-stud connector, and is operable to attach a device thereto. A drive tool includes an open interior region for receiving the attachment portion therein. The head of the flow drill screw includes an external drive interface, disposed on an exterior surface of the head, radially about the rotation axis, which mates with an internal drive interface of the drive tool, to transmit torque therebetween.

Abstract: A body structure of a vehicle includes a bulkhead, and a frame rail extending forward from the bulkhead along a longitudinal centerline. A powertrain system is disposed laterally inboard of the frame rail relative to the longitudinal centerline. The frame rail includes a flared section, a splayed section, and a reinforcing member. The flared section curves laterally outboard, away from the longitudinal centerline. The splayed section includes a variable cross sectional area that increases with an increase in distance from the bulkhead. The reinforcing member is operable to increase lateral stiffness in the frame rail, in a direction transverse to the longitudinal centerline. The frame rail is operable to deform into contact with the powertrain system in response to a load applied to a forward end of the body structure and laterally offset from the longitudinal centerline, to generate a lateral force in the body structure.

Abstract: A method of manufacturing a structural support member for a vehicle includes forming a first portion, forming a second portion, and connecting the first portion and the second portion together. The first portion and the second portion may be formed from one of an aluminum material, a magnesium material, a cold-formable steel material, a glass fiber composite material, or a plastic material. The first portion and the second portion are connected together such that the second portion is disposed in a tensile loading condition in response to an impact load applied to the first portion. A laminate layer is attached to the second portion. The laminate layer includes an ultra high strength material having a yield strength equal to or greater than five hundred fifty (550) MPa. The laminate layer may include, for example, an iron based glassy metal foil or an iron based glassy metal foil fabric.

Abstract: A sound-damped vehicle panel assembly, such as a dash panel, is attached to a structural member with one or more weld joints. The vehicle panel assembly may include a main panel member, a sound-damping patch, and a sound-damping adhesive layer arranged therebetween, where the patch covers at least a portion of an acoustically active region of the main panel member. The weld joints that attach the vehicle panel assembly to the structural member are preferably located at weld openings formed in the sound-damping patch and/or the sound-damping adhesive layer so that the weld joint can be formed without melting and vaporizing the adhesive during the welding operation, as such an operation would likely require additional ventilation equipment and could impact the quality of the weld joint.

Abstract: An impact receiving structure in a motor vehicle includes a vehicle frame having left and right frame rails extending longitudinally and cross frame rails extending transversely between the left and right frame rails. A vehicle body is mounted on the vehicle frame and has a transverse bulkhead and left and right A-pillars connected to the bulkhead. Left and right upper rails extend longitudinally above the front wheels and outboard of the left and right frame rails and are connected respectively to the left and right frame rails by left and right braces. Left and right deflector devices are mounted on the left and right frame rails forwardly of the front wheels and extend outwardly from the left and right frame rails to receive an impact force and transmit the impact force into the frame that would otherwise transmit through the left and right upper rail structures.

Abstract: A method of evaluating the structural integrity of a component such as a vehicle component includes receiving signals from radio frequency identification (RFID) tags embedded in the component. The signals received are then compared to stored data indicative of sets of signals and that is correlated with different physical conditions of the component. A level of structural integrity of the component is then determined based on the comparison. The RFID tags may be wirelessly activated by an RFID reader to generate the signals. The comparison and determination may be carried out by a processor of an RFID reader. A system for evaluating the structural integrity of a component is also provided.

Abstract: A reinforced structural assembly includes a first vehicle component and a second vehicle component attached to the first vehicle component to define a substantially closed cavity. An acoustic foam member is contained within a container, also referred to as a vehicle pouch, containing the acoustic foam member and is made of a material that has a predetermined strength. A sealant with adhesive properties is included on at least a portion of an outer surface of the container, and is impregnated within or coated onto the container. The container and the acoustic foam member substantially fill the cavity so that the outer surface of the container contacts at least a portion of an inner surface of the vehicle components and the sealer seals the acoustic foam member and adheres the container to the inner surface of the attached vehicle components. A method of reinforcing vehicle components is provided.

Abstract: A sound-damped vehicle panel assembly, such as a dash panel, is attached to a structural member with one or more weld joints. The vehicle panel assembly may include a main panel member, a sound-damping patch, and a sound-damping adhesive layer arranged therebetween, where the patch covers at least a portion of an acoustically active region of the main panel member. The weld joints that attach the vehicle panel assembly to the structural member are preferably located at weld openings formed in the sound-damping patch and/or the sound-damping adhesive layer so that the weld joint can be formed without melting and vaporizing the adhesive during the welding operation, as such an operation would likely require additional ventilation equipment and could impact the quality of the weld joint.

Abstract: A reinforcement and method for reinforcing a hollow tubular structure includes a first sheet of flexible fiber material impregnated with resin. The first sheet is rolled into a tubular shape and a seam is provided between first and second lateral edges of the first sheet to form a tubular reinforcement. An inflatable bladder extends through the tubular reinforcement and is inflated to press the tubular reinforcement into contact with the inside wall of the tubular structure. Curing of the resin will bond the first sheet to the inside wall to reinforce the tubular structure. The first sheet can have a region of built-up thickness to provide additional reinforcement. The seam between the lateral edges of the first sheet can be a separable seam that separates when the bladder is inflated to allow the first sheet to contact with a region of the tubular structure that is of larger circumference than the circumference of the tubular reinforcement.

Abstract: The invention concerns a vehicle body panel. The vehicle body panel, such as a floor pan, may have a generally planar portion adapted to be located adjacent to and conceal a vehicle component, such as a fuel pump module. An access portion is located within and extends out of plane of the generally planar portion, and includes a periphery, wherein the access portion is integral with the generally planar portion. Also, a cutting guide feature extends around it adjacent to the periphery.

Abstract: A rotatable spare wheel carrier is provided for a rear compartment of a vehicle. The rotatable spare wheel carrier includes a base portion adapted to engage a spare wheel and be spaced above a base wall of a recess in a rear compartment of a vehicle. The rotatable spare wheel carrier also includes a leg portion extending downwardly and longitudinally from the base portion and a foot portion extending longitudinally from the leg portion and adapted to be secured to the base wall. The rotatable spare wheel carrier further includes a living hinge between the base portion and the leg portion to allow the base portion to rotate relative to the leg portion upon an impact on a rear of the vehicle.