Abstract: A structural member for use in a vehicle body and frame assembly includes an internal air tank for supplying pressurized air to an auxiliary device, such as an active suspension for the vehicle. The internal air tank may be generally cup-shaped, including a closed end portion, a plurality of side portions, and an outwardly extending flange portion that extends about an open end portion. The flange portion is secured to a first portion of the closed channel structural member to define an air-tight chamber. The chamber is adapted to selectively receive and store a quantity of a pressurized fluid therein, and further to selectively discharge such pressurized fluid to an auxiliary device. An opening can be formed through the structural member to facilitate fluid communication with the chamber. Alternately, the internal air tank may include a flexible bladder defining an air-tight chamber.

Abstract: A joint between two or more structural members in a vehicular body and frame assembly facilitates the application of a coating of a material thereto after assembly of the joint. The first and second structural members have respective outer surfaces provided thereon. A spacer is provided either as a portion of a reinforcement member disposed within the first structural member or integrally with the first structural member. The first structural member is connected to the second structural member with the spacer therebetween so as to define a joint defining a gap between the outer surfaces of the first and second structural members. Lastly, a coating of a material is applied to the outer surfaces of the first and second structural members.

Abstract: A structural member for use in such a vehicle body and frame assembly includes an internal air tank for supplying pressurized air to an auxiliary device, such as an active suspension for the vehicle. The internal air tank may be generally cup-shaped, including a closed end portion, a plurality of side portions, and an outwardly extending flange portion that extends about an open end portion. The flange portion is secured to a first portion of the closed channel structural member to define an air-tight chamber. The chamber is adapted to selectively receive and store a quantity of a pressurized fluid therein, and further to selectively discharge such pressurized fluid to an auxiliary device. An opening can be formed through the structural member to facilitate fluid communication with the chamber. Alternately, the internal air tank may include a flexible bladder defining an air-tight chamber.

Abstract: A method is disclosed for manufacturing a vehicle body and frame assembly including a pair of side rails, each of which is formed from a single closed channel structural member that extends the entire length of the vehicle body and frame assembly and is deformed into a desired shape by hydroforming. The first step in the process is to provide a length of stock material, preferably a tubular metallic workpiece, having a predetermined length. The tubular workpiece is then typically pre-bent by a conventional tube bending apparatus to have some or all of the bends in the side rails to be formed. The bends initially formed in the workpiece during this pre-bending step usually do not have the exact angles and shapes which result in the final product. Rather, this initial pre-bending operation is performed to facilitate the insertion of the workpiece within a die cavity defined by cooperating die sections of a hydroforming die.

Abstract: A method of manufacturing a vehicle frame assembly includes the initial steps of providing first and second side rails and providing first and second cross members. Each of the first and second cross members has first and second ends extending from a central portion. A desired torsional stiffness is determined for the first cross member. In response to this determination, the first and second ends of the first cross member are enlarged so as to achieve the desired torsional stiffness for the cross member. A similar process can be conducted for the second cross member. Then, the first ends of the first and second cross members are secured to the first side rail, and the second ends of the first and second cross members are secured to the second side rail to form a vehicle frame assembly.

Abstract: A skid plate and cross member assembly for a vehicular frame includes a skid plate having a platform and a cross member having a body. A locking element, preferably having holes or slots, is formed in the body of the cross member. A moldable material in a moldable state is placed in a mold for the skid plate. The cross member is pressed into the moldable platform of the skid plate so that the locking element is immersed and the moldable material fills the voids of the locking element. After the moldable material has cured, the cross member is interlocked with the skid plate to form a lightweight skid plate and cross member assembly. This assembly is secured to side rails of a vehicular frame to protect lower components of a vehicle.