Abstract: A bumper beam includes an aluminum tubular carrier that is wrapped with a plurality of carbon fiber fabric layers. The carbon fiber fabric is pre-impregnated with a two-part epoxy resin system. The layers of carbon fiber fabric are applied in an alternating series with the carbon fibers in adjacent layers extending perpendicularly relative to the carbon fibers in adjacent layers.

Abstract: A panoramic vehicle roof module assembly is provided with front and rear cross members. A pair of extruded side rails are each mounted to the cross members. Each side rail has a front integrated roof track, a rear integrated roof track and an integrated sun shade track, each track formed therein along its length. A roof panel is supported by one of the integrated roof tracks of the side rails to interface with the front cross members. An intermediate cross member is mounted to the side rails and is interfaced with the roof panel. A second panel is provided mounted to the side rails to interface with the rear cross member and the intermediate cross member. The side rails each include an integrated support flange to mount the assembly to a vehicle. A method of manufacturing a panoramic vehicle roof module assembly is provided.

Abstract: A method of conducting vehicle usage data analysis is provided. The method includes providing usage data about at least one vehicle to a database. The usage data may be analyzed and compared to a member of a set of vehicle development models to determine whether to update a vehicle development model. The usage data may also be analyzed to determine whether to transmit a communication to a vehicle.

Abstract: A friction stir spot welding tool and a self-piercing riveting tool are disclosed for joining parts. The parts are clamped between a head and anvil support of the friction stir spot welding tool or the self-piercing riveting tool. A plurality of clamping and heating modules are attached to an attachment fixture on the head and the anvil support that heats the area around the pin of the friction stir spot welding tool or self-piercing riveting tool prior to and during the joining operation.

Abstract: A method of conducting vehicle usage data analysis is provided. The method includes providing usage data about at least one vehicle to a database. The usage data may be analyzed and compared to a member of a set of vehicle development models to determine whether to update a vehicle development model. The usage data may also be analyzed to determine whether to transmit a communication to a vehicle.

Abstract: A vehicle roof module includes a front extruded cross member, a first pair of nodes each received in an end region of the front cross member, a first and a second extruded side rail with each end region receiving one of the first pair of nodes, a second pair of nodes each received in another end region of the first and second rails, a rear extruded cross member with each end region receiving one of the second pair of nodes, and a panel mounted to the front cross member, rear cross member, and first and second side rail. Each end region of each side rail defines an interior hollow portion and has at least one nodule extending from the side rail into the hollow portion to maintain a bond gap between the side rail and the node received into the side rail end region for receiving adhesive.

Abstract: A vehicle roof module includes a front extruded cross member, a first pair of nodes each received in an end region of the front cross member, a first and a second extruded side rail with each end region receiving one of the first pair of nodes, a second pair of nodes each received in another end region of the first and second rails, a rear extruded cross member with each end region receiving one of the second pair of nodes, and a panel mounted to the front cross member, rear cross member, and first and second side rail. Each end region of each side rail defines an interior hollow portion and has at least one nodule extending from the side rail into the hollow portion to maintain a bond gap between the side rail and the node received into the side rail end region for receiving adhesive.

Abstract: A panoramic vehicle roof assembly is provided with a first cross member and a second cross member. Each of the first and second cross members is adapted to be mounted to a vehicle body at spaced apart locations. A first extruded side rail and a second extruded side rail are respectively mounted to one of the first and second cross members at spaced apart locations. Each first and second side rail has a drive integrated roof track and an idler integrated roof track. At least one roof panel is supported by at least one of the integrated roof tracks of the side rails. A method of manufacturing a panoramic vehicle roof module assembly is provided.

Abstract: A panoramic vehicle roof module assembly is provided with front and rear cross members. A pair of extruded side rails are each mounted to the cross members. Each side rail has a front integrated roof track, a rear integrated roof track and an integrated sun shade track, each track formed therein along its length. A roof panel is supported by one of the integrated roof tracks of the side rails to interface with the front cross members. An intermediate cross member is mounted to the side rails and is interfaced with the roof panel. A second panel is provided mounted to the side rails to interface with the rear cross member and the intermediate cross member. The side rails each include an integrated support flange to mount the assembly to a vehicle. A method of manufacturing a panoramic vehicle roof module assembly is provided.

Abstract: A panoramic vehicle roof assembly is provided with a first cross member and a second cross member. Each of the first and second cross members is adapted to be mounted to a vehicle body at spaced apart locations. A first extruded side rail and a second extruded side rail are respectively mounted to one of the first and second cross members at spaced apart locations. Each first and second side rail has a drive integrated roof track and an idler integrated roof track. At least one roof panel is supported by at least one of the integrated roof tracks of the side rails. A method of manufacturing a panoramic vehicle roof module assembly is provided.

Abstract: A structural polymer insert. The insert includes a substrate having a surface and an adhesive with the substrate being an admixture of a polypropylene component and a glass fiber component. The surface has a plurality of oxygen atoms, optionally introduced by air plasma, in an amount of 1 to 60 atomic percent of all the atoms present on the surface. The foam adhesive is attached to the surface through one or more reactive moieties resulted from oxidative action of the oxygen atoms.

Abstract: A method of making a vehicle door assembly by assembling a super-plastic formed inner door panel with a super-plastic formed outer panel. A flanging and roll hemming tool are used to form a hem flange to secure the outer door panel to the inner door panel. A room temperature curable two-part epoxy adhesive is used to lock the inner and outer door panels together. The epoxy adhesive is permitted to cure before the assembly is heated in electro-operations or paint ovens. Hinge and striker attachment areas are provided that are not substantially thinned or stretched during the super-plastic forming process so as to preserve the strength of the inner and outer door panels in such areas.

Abstract: A method of securing body panels to a space frame for a vehicle is disclosed. The body panels are secured to rivet nuts that are assembled to frame members. The location of the rivet nuts or rivet nuts supporting surface is measured and the rivet nuts are milled or machined to correspond to reference body coordinates. The milled rivet nuts function as a integral shim pack and obviate the need for shims between the space frame and body panels.

Abstract: A process or method of making a vehicle passenger compartment floor component such as a central tunnel or rocker panel. Base extrusion pieces and upper pieces are secured by a friction stir welding process to each other and to a portion of a passenger compartment floor. Upper pieces may be formed by extrusion or may be formed by a sheet forming process and secured to base extrusion pieces by means of the friction stir welding process.

Abstract: A method of securing body panels to a space frame for a vehicle is disclosed. The body panels are secured to rivet nuts that are assembled to frame members. The location of the rivet nuts or rivet nuts supporting surface is measured and the rivet nuts are milled or machined to correspond to reference body coordinates. The milled rivet nuts function as a integral shim pack and obviate the need for shims between the space frame and body panels.

Abstract: A method of making a vehicle door assembly by assembling a super-plastic formed inner door panel with a super-plastic formed outer panel. A flanging and roll hemming tool are used to form a hem flange to secure the outer door panel to the inner door panel. A room temperature curable two-part epoxy adhesive is used to lock the inner and outer door panels together. The epoxy adhesive is permitted to cure before the assembly is heated in electro-operations or paint ovens. Hinge and striker attachment areas are provided that are not substantially thinned or stretched during the super-plastic forming process so as to preserve the strength of the inner and outer door panels in such areas.

Abstract: A crush rail or other structural member of a vehicle is provided with crush triggers. The crush triggers are formed by heating localized areas of the crush rail or other part and allowing them to cool slowly to provide increased ductility and reduced strength in a localized region. The crush rail is designed to collapse in a series of convolutions in a regular and repeated pattern. Crush triggers may be provided on body pillars, steering columns, drive shafts, engine support cradles, and other parts of a vehicle. A plurality of crush triggers may be provided on a single structural member depending upon impact absorption requirements.

Abstract: A crush rail or other structural member of a vehicle is provided with crush triggers. The crush triggers are formed by heating localized areas of the crush rail or other part and allowing them to cool slowly to provide increased ductility and reduced strength in a localized region. The crush rail is designed to collapse in a series of convolutions in a regular and repeated pattern. Crush triggers may be provided on body pillars, steering columns, drive shafts, engine support cradles, and other parts of a vehicle. A plurality of crush triggers may be provided on a single structural member depending upon impact absorption requirements.

Abstract: A process or method of making a vehicle passenger compartment floor component such as a central tunnel or rocker panel. Base extrusion pieces and upper pieces are secured by a friction stir welding process to each other and to a portion of a passenger compartment floor. Upper pieces may be formed by extrusion or may be formed by a sheet forming process and secured to base extrusion pieces by means of the friction stir welding process.

Abstract: A body panel assembly having an inner panel and an outer panel. The outer panel has a greater coefficient of thermal expansion than the inner panel. An adhesive is disposed between the inner panel and the outer panel. A portion of the outer panel is hemmed to the inner panel to join the inner and outer panels together. A scrim pad may be provided between inner and outer panels to inhibit galvanic corrosion.