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: 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 frame portion for a vehicle includes a pillar component extending along a first direction and a beam component at least partially extending along a second direction substantially orthogonal to the first direction. The beam component has a rear end proximate the pillar component. The frame portion further includes a bracket coupled between the pillar component and the rear end of the beam component. The bracket spaces the beam component from the pillar component.

Abstract: A vehicle having a roof panel connectedly extending inwardly from a body structure and a tether connectedly extending between the roof panel and body structure. The vehicle may be a pickup truck having a side body structure with an aluminum alloy internal panel and roof panel connected together to make up a portion of a passenger compartment of a cab. The tether assembly may have a mounting component adhesively connected to the roof panel and a tether rope connected to the mounting component and to the internal panel. The mounting component of the tether assembly may be taped to the roof panel. The mounting component may have a heat curing adhesive. The connector of the tether assembly may be fastened to the side body structure using a threaded fastener. The heat curing adhesive may be activated with an oven to secure the mounting component to the roof panel.

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 having a roof panel connectedly extending inwardly from a body structure and a tether connectedly extending between the roof panel and body structure. The vehicle may be a pickup truck having a side body structure with an aluminium alloy internal panel and roof panel connected together to make up a portion of a passenger compartment of a cab. The tether assembly may have a mounting component adhesively connected to the roof panel and a tether rope connected to the mounting component and to the internal panel. The mounting component of the tether assembly may be taped to the roof panel. The mounting component may have a heat curing adhesive. The connector of the tether assembly may be fastened to the side body structure using a threaded fastener. The heat curing adhesive may be activated with an oven to secure the mounting component to the roof panel.

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 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 reinforcement received between facing surfaces of adjacent panels that may be part of a hinge pillar of a vehicle such as a pickup truck and the panels may be aluminum. The reinforcement may be a one-piece molded structure. The reinforcement includes ribs that extend between the facing surfaces in a lattice arrangement defining a plurality of cells. The cells may have a number of transverse walls defining a perimeter of a polygon. The polygonal cells may have a facing wall on one side of the cell closing the cell. The facing wall may have an adhesive that is applied to the reinforcement and expanded in a paint bake oven to secure the reinforcement to the adjacent panels.

Abstract: A frame portion for a vehicle includes a pillar component extending along a first direction and a beam component at least partially extending along a second direction substantially orthogonal to the first direction. The beam component has a rear end proximate the pillar component. The frame portion further includes a bracket coupled between the pillar component and the rear end of the beam component. The bracket spaces the beam component from the pillar component.

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 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 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.

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 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 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.

Abstract: A modular body structure and a method for assembling a body structure in a vehicle includes fitting a pillar having first and second ends between a roof rail and a lower support such that the first end is disposed below a top of the roof rail. The pillar is fastened to the roof rail and the lower support with first threaded fasteners by friction drilling holes through the pillar and the roof rail and the lower support.

Abstract: A vehicle front end structure includes a hinge pillar having laterally spaced first and second vertical mounting surfaces that extend in a longitudinal direction. The vehicle also includes a tubular support member having a first wall secured to the first vertical mounting surface and a second wall secured to the second vertical mounting surface. The second wall extends rearward of the first wall and is secured to the hinge pillar laterally outboard of the first wall. A notched portion through at least one horizontal wall interconnecting the first and second walls of the tubular support may operate as a buckling location of the tubular support.

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 body structure for a vehicle includes a cowl side defining a first vertical and longitudinal plane. A hinge pillar including a tab portion is attached to the cowl side in the first plane. The hinge pillar includes a stepped surface defining a second vertical and longitudinal plane that is offset outwardly from the first plane and parallel to the first plane. A front end rail includes an inner sidewall fastened to the cowl side and an outer sidewall fastened to the stepped surface the stepped surface. The longitudinal loads applied to the front end rail are transferred in shear to the hinge pillar and cowl side.