Abstract: A vehicle includes a body structure, a side bracket secured to the body structure, and a spacer bracket secured to the side bracket. The spacer bracket extends in a lateral direction toward an interior of the vehicle. The vehicle further includes a roof bow secured to the spacer bracket. The roof bow extends in the lateral direction toward the interior of the vehicle. The roof bow may be secured to the spacer bracket through at least one fastener adapted to shear under a predetermined shear stress. The roof bow may be secured to the spacer bracket such that a distal end of the roof bow is disposed in spaced relation relative to a distal end of the of the spacer bracket. The roof bow may be secured to a K-brace which extends toward roof rails.

Abstract: A vehicle canopy includes a vehicle body defining a roof opening. A roof is connected to the vehicle body across the roof opening. A headliner is supported by at least one of the vehicle body and the roof. A frame is supported by the vehicle body. A fabric partition is engaged with the frame and extends across the roof opening between the headliner and the roof. The fabric partition may assist in preventing occupant test dummies and/or other objects from moving through the roof opening.

Abstract: A vehicle roof structure assembly includes a mounting bracket having a first aperture disposed therethrough. The vehicle roof structure assembly further includes a roof bow having a longitudinal body portion defining an inner channel. The longitudinal body portion includes a bottom wall having a second aperture axially aligned with the first aperture. The vehicle roof structure assembly further includes an insert block disposed within the inner channel of the roof bow. The insert block defines a third aperture disposed through a thickness of the insert block. The third aperture is axially aligned with the first aperture and the second aperture. The vehicle roof structure assembly further includes a fastener disposed through the first aperture, the second aperture, and the third aperture to rigidly secure the roof bow to the mounting bracket, and to rigidly secure the insert block to the roof bow.

Abstract: A vehicle rocker assembly is provided. The vehicle rocker assembly may include an outer panel, a side sill, and an insert. The side sill may define at least two cavities with the outer panel. The insert may be disposed in the cavities. The insert may include a longitudinally extending U-shaped carrier and a plurality of reinforcement members attached to the U-shape carrier. The plurality of reinforcement members may be spaced apart from a bottom of the U-shaped carrier by a predetermined distance.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A method of making a vehicular subassembly includes a step for providing a roof header comprising a hollow member having a long axis, a short axis, and an outer surface that includes a flange. The method also includes a step of stretch bending the member such that the outer surface is substantially in tension and curved in the short axis direction. The method further includes a step of cutting a plurality of notched elements into the flange to reduce strain from the stretch bending step. In some aspects, the step of cutting can be conducted before the stretch bending to reduce strain in the header associated with the subsequent stretch bending.

Abstract: A vehicle roof support structure including a pair of reinforcing truss members. The roof support structure includes a header, a roof bow, right and left roof rails, and a center roof support. The trusses form triangular reinforcing structures on the driver-side and passenger-side.

Abstract: A vehicle roof structure and door opening panel structure is disclosed that is reinforced with an upper reinforcement strip and a lower reinforcement strip. The roof panel, door opening panel and reinforcement strips are attached by an adhesive and by a plurality of fasteners. The fasteners are received in pierce nuts that are preassembled to the lower reinforcing strip.

Abstract: An automotive aluminum alloy component assembly includes a first vehicle component defining a first joint region and a first cutout. The assembly also includes a second vehicle component defining a second joint region. The assembly also includes a third vehicle component defining a third joint region. Portions of the first and third joint region sandwich the second joint region. A first self-piercing rivet is disposed within the second and third components and aligned with the first cutout.

Abstract: A vehicle assembly is provided. The vehicle assembly includes a roof panel, a bodyside panel and a bolt. The roof panel and bodyside panel collectively form a roof ditch. The bolt includes a stud that has first and second distal portions. The first and second distal portions include first and second threaded portions, respectively. The first distal portion extends outwardly from one of the roof and bodyside panels and the second distal portion extending outwardly from the other of the roof and bodyside panels and into the roof ditch.

Abstract: A vehicle body assembly including a frame with an outrigger secured to the frame below a passenger compartment. The passenger compartment includes a plurality of pillars supporting a roof, a first rocker assembly and a second rocker assembly disposed on opposite sides of the passenger compartment. The outrigger is secured to the frame below the passenger compartment, inboard of the rocker assembly and outboard of the roof to protect the roof in side impact collisions. The outriggers transfer the side impact loads to the frame rails that are disposed inboard of the roof rails.

Abstract: A vehicle canopy includes a vehicle body defining a roof opening. A roof is connected to the vehicle body across the roof opening. A headliner is supported by at least one of the vehicle body and the roof. A frame is supported by the vehicle body. A fabric partition is engaged with the frame and extends across the roof opening between the headliner and the roof. The fabric partition may assist in preventing occupant test dummies and/or other objects from moving through the roof opening.

Abstract: A vehicle roof structure and door opening panel structure is disclosed that is reinforced with an upper reinforcement strip and a lower reinforcement strip. The roof panel, door opening panel and reinforcement strips are attached by an adhesive and by a plurality of fasteners. The fasteners are received in pierce nuts that are preassembled to the lower reinforcing strip.

Abstract: A vehicle canopy includes a vehicle body defining a roof opening. A roof is connected to the vehicle body across the roof opening. A headliner is supported by at least one of the vehicle body and the roof. A frame is supported by the vehicle body. A fabric partition is engaged with the frame and extends across the roof opening between the headliner and the roof. The fabric partition may assist in preventing occupant test dummies and/or other objects from moving through the roof opening.

Abstract: An aluminum alloy vehicle structural component defining an out-of-plane aperture with its main portion. A recessed portion is inset from the main portion having a bed sub-portion out-of-plane with the main portion that defines the aperture. The recessed portion also provides a strain hardened sub-portion, or stiffened ring of material, around the aperture. When the main portion is subjected to in-plane tension due to bending, the strain primarily concentrates along the strain hardened sub-portion (the stiffened ring) and by-passes the aperture. As a result the perimeter of the aperture undergoes less straining than if the aperture was in-plane with the main portion. The out-of-plane aperture, the bed sub-portion surrounding the aperture, and the strain hardened sub-portion surrounding the bed sub-portion may improve the overall structural robustness of the aluminum alloy structural component when subjected to in-plane tension.

Abstract: A vehicle assembly is provided. The vehicle assembly includes a roof panel, a bodyside panel and a bolt. The roof panel and bodyside panel collectively form a roof ditch. The bolt includes a stud that has first and second distal portions. The first and second distal portions include first and second threaded portions, respectively. The first distal portion extends outwardly from one of the roof and bodyside panels and the second distal portion extending outwardly from the other of the roof and bodyside panels and into the roof ditch.

Abstract: A hydro-formed body side rail is assembled by a bracket to a front header. The front header is an extruded cross-car structural support that is joined to the body side rail by a framed joint. A gap is defined between the body side outer panel and the hydro-formed side rail relative to a lateral end of a front header. Side impact test loads are applied initially to the body side rail and compress the bracket. Compression of the bracket closes the gap and the impact loads are applied to the cross-car structural support.

Abstract: A vehicle body assembly including a frame with an outrigger secured to the frame below a passenger compartment. The passenger compartment includes a plurality of pillars supporting a roof, a first rocker assembly and a second rocker assembly disposed on opposite sides of the passenger compartment. The outrigger is secured to the frame below the passenger compartment, inboard of the rocker assembly and outboard of the roof to protect the roof in side impact collisions. The outriggers transfer the side impact loads to the frame rails that are disposed inboard of the roof rails.

Abstract: A vehicle roof frame includes an adhering structure having an adhesive carrier and an expanding structural adhesive coupled to at least a portion of an outer surface of the adhesive carrier. The expanding structural adhesive includes an installation state and a structural state, and the structural state has a larger volume than the installation state. The vehicle roof frame also includes a plurality of vehicle frame members that cooperate to form a frame joint and a joint cavity defined within the frame joint. The adhering structure is disposed within the joint cavity and the adhesive carrier and the expanding structural adhesive in the structural state substantially occupies the joint cavity and fixably couples the plurality of framing members such that the frame joint is free of supplemental mechanical connections proximate the joint cavity.