Abstract: A vehicle underbody includes a system of connected unitized underbody components including a front quadrant system having a left front unitized underbody component and a right front unitized underbody component, a center system, and a rear quadrant system having a left rear unitized underbody component and a right rear unitized underbody component. A first rail element is loosely connected to the left front unitized underbody component and the left rear unitized underbody component, and a second rail element is loosely connected to the right front unitized underbody component and the right rear unitized underbody component.

Abstract: A method to join three panels together for a motor vehicle includes one or more of the following: layering the three panels, the three panels including a first panel, a second panel, and a third panel, the second panel being positioned between the first panel and the third panel, the third panel having a higher electrical conductivity than the first panel and the second panel; joining the first panel and the second panel together; and joining the third panel to the first panel and the second panel.

Abstract: An extruded rail assembly including a first multi-channel extrusion having at least two tubular channels connected by a center rib, and having a joining end configured for joining at a predetermined angle to a joining end of a second multi-channel extrusion. The second multi-channel extrusion includes at least two tubular channels connected by a center rib, and having a joining end configured for joining at the predetermined angle to the joining end of first multi-channel extrusion. The joining ends of the first and second multi-channel extrusions are configured such that the center ribs complementarily engage as a joining surface.

Abstract: A vehicle body-variant adaptable shock tower system for a vehicle body structure having an axis, a vehicle frame rail arranged along the axis, a bulkhead arranged orthogonally relative to the frame rail. The system includes a shock tower spaced apart from the bulkhead and fixed to the frame rail. The system also includes a shock tower cap defining a plurality of receivers and a plurality of braces, wherein the number of braces corresponds to the body-variant. Each brace extends from the shock tower through a respective one of the receivers to the bulkhead, and is fixed to the shock tower and the bulkhead. The system additionally includes an adhesive applied between the shock tower cap, the plurality of braces, and the shock tower to thereby bond the shock tower cap, the braces, and the shock tower to each other and reinforce the vehicle body structure.

Abstract: A load impact management system for a vehicle includes a plurality of cross-vehicle support members extending from a first side of the vehicle to a second side of the vehicle opposite the first side of the vehicle, a shock tower spaced apart from the plurality of cross-vehicle support members and fixed to the vehicle frame rail, a first structural member extending along a first plane, a second structural member extending along a second plane separate from the first plane, and a third structural member extending along a third plane separate from the first and second planes. The first structural member defines a first load path between the center tunnel and the shock tower, the second structural member defines a second load path between the center tunnel and the shock tower, and the third structural member defines a third load path between the center tunnel and the vehicle frame rail.

Abstract: A side impact load management system for a vehicle having a vehicle frame includes a plurality of cross-vehicle support members extending from a first side of the vehicle to a second side of the vehicle. A first structural member extends in a first vertical plane parallel to a vehicle body axis defined by the vehicle frame and coupled to the vehicle frame, the first structural member connecting the plurality of cross-vehicle support members on the first side of the vehicle. A second structural member extends in a second vertical plane parallel to the vehicle body axis defined by the vehicle frame and coupled to the vehicle frame, the second structural member connecting the plurality of cross-vehicle support members on the second side of the vehicle. The first and second structural members are configured to transfer a side impact load simultaneously to the plurality of cross-vehicle support members.

Abstract: A system for providing structural transmittal of force through a vehicle body of a mid-engine vehicle is provided. The system includes an elongated single member torsional box spanning a passenger compartment from a vehicle-forward portion of the passenger compartment to a vehicle-rearward portion of the passenger compartment, parallel to a longitudinal axis of the vehicle body, and laterally centered upon a longitudinal centerline of the vehicle body. The system further includes four rails in a vehicle-forward position relative to the elongated single member torsional box, parallel to the longitudinal axis of the vehicle body, and offset from the elongated single member torsional box. The system further includes four diagonal support members, each diagonal support member being connected at a first end to one of the four rails and at a second end to the elongated single member torsional box.

Abstract: A bulkhead for a vehicle body structure includes a panel. The panel has a contour defined by a contour length and characterized by an open section having three surfaces in a cross-sectional view. The bulkhead also includes a support member embedded in the panel. The support member includes an external form configured to interface with and match at least two of the three surfaces of the contour. The support member also includes a support member length configured to fit within the contour length and a boxed cross-section having a substantially uniform shape along the support member length. The bulkhead additionally includes an adhesive applied between the external form of the support member and the interfacing surfaces of the contour to thereby bond the support member to the panel and reinforce the bulkhead. A vehicle having a structure with such a bulkhead is also considered.

Abstract: A system for providing structural transmittal of force through a vehicle body of a mid-engine vehicle is provided. The system includes an elongated single member torsional box spanning a passenger compartment. The system further includes two vehicle body side members spanning an outer lateral edge of the passenger compartment. The system further includes four rails parallel to the longitudinal axis of the vehicle body. The system further includes four inner diagonal support members, each inner diagonal support member being connected at a first end to one of the four rails and on the second end to the elongated single member torsional box and being configured to transmit force from the one of the four rails to the single member torsional box. The system further includes four outer diagonal support members, each outer diagonal support member being configured to transmit force to one of the vehicle body side members.

Abstract: A load impact management system for a vehicle includes a plurality of cross-vehicle support members extending from a first side of the vehicle to a second side of the vehicle opposite the first side of the vehicle, a shock tower spaced apart from the plurality of cross-vehicle support members and fixed to the vehicle frame rail, a first structural member extending along a first plane, a second structural member extending along a second plane separate from the first plane, and a third structural member extending along a third plane separate from the first and second planes. The first structural member defines a first load path between the center tunnel and the shock tower, the second structural member defines a second load path between the center tunnel and the shock tower, and the third structural member defines a third load path between the center tunnel and the vehicle frame rail.

Abstract: A side impact load management system for a vehicle having a vehicle frame includes a plurality of cross-vehicle support members extending from a first side of the vehicle to a second side of the vehicle. A first structural member extends in a first vertical plane parallel to a vehicle body axis defined by the vehicle frame and coupled to the vehicle frame, the first structural member connecting the plurality of cross-vehicle support members on the first side of the vehicle. A second structural member extends in a second vertical plane parallel to the vehicle body axis defined by the vehicle frame and coupled to the vehicle frame, the second structural member connecting the plurality of cross-vehicle support members on the second side of the vehicle. The first and second structural members are configured to transfer a side impact load simultaneously to the plurality of cross-vehicle support members.

Abstract: A bulkhead for a vehicle body structure includes a panel. The panel has a contour defined by a contour length and characterized by an open section having three surfaces in a cross-sectional view. The bulkhead also includes a support member embedded in the panel. The support member includes an external form configured to interface with and match at least two of the three surfaces of the contour. The support member also includes a support member length configured to fit within the contour length and a boxed cross-section having a substantially uniform shape along the support member length. The bulkhead additionally includes an adhesive applied between the external form of the support member and the interfacing surfaces of the contour to thereby bond the support member to the panel and reinforce the bulkhead. A vehicle having a structure with such a bulkhead is also considered.

Abstract: A system for providing structural transmittal of force through a vehicle body of a mid-engine vehicle is provided. The system includes an elongated single member torsional box spanning a passenger compartment. The system further includes two vehicle body side members spanning an outer lateral edge of the passenger compartment. The system further includes four rails parallel to the longitudinal axis of the vehicle body. The system further includes four inner diagonal support members, each inner diagonal support member being connected at a first end to one of the four rails and on the second end to the elongated single member torsional box and being configured to transmit force from the one of the four rails to the single member torsional box. The system further includes four outer diagonal support members, each outer diagonal support member being configured to transmit force to one of the vehicle body side members.

Abstract: A vehicle body-variant adaptable shock tower system for a vehicle body structure having an axis, a vehicle frame rail arranged along the axis, a bulkhead arranged orthogonally relative to the frame rail. The system includes a shock tower spaced apart from the bulkhead and fixed to the frame rail. The system also includes a shock tower cap defining a plurality of receivers and a plurality of braces, wherein the number of braces corresponds to the body-variant. Each brace extends from the shock tower through a respective one of the receivers to the bulkhead, and is fixed to the shock tower and the bulkhead. The system additionally includes an adhesive applied between the shock tower cap, the plurality of braces, and the shock tower to thereby bond the shock tower cap, the braces, and the shock tower to each other and reinforce the vehicle body structure.

Abstract: A system for providing structural transmittal of force through a vehicle body of a mid-engine vehicle is provided. The system includes an elongated single member torsional box spanning a passenger compartment from a vehicle-forward portion of the passenger compartment to a vehicle-rearward portion of the passenger compartment, parallel to a longitudinal axis of the vehicle body, and laterally centered upon a longitudinal centerline of the vehicle body. The system further includes four rails in a vehicle-forward position relative to the elongated single member torsional box, parallel to the longitudinal axis of the vehicle body, and offset from the elongated single member torsional box. The system further includes four diagonal support members, each diagonal support member being connected at a first end to one of the four rails and at a second end to the elongated single member torsional box.

Abstract: An interlocking body and floor pan assembly for a below-floor energy stored vehicle includes a vehicle structural assembly having a front compartment section connected to a rear compartment section using first and second rocker members. The front compartment section includes a compartment front cross-beam and the rear compartment section includes a compartment rear cross-beam oriented parallel to the compartment front cross-beam. The vehicle structural assembly defines a bucket configuration having faces of the compartment front cross-beam and the compartment rear cross-beam angularly oriented from an upper outboard edge downwardly pitching to a lower inboard edge. A prefabricated sub-floor assembly seats on flange structure and is positioned with a clearance to the bucket configuration of the vehicle structural assembly. An outer perimeter of the sub-floor assembly is larger than an inner perimeter of the vehicle structural assembly where the sub-floor assembly contacts the vehicle structural assembly.

Abstract: An interlocking body and floor pan assembly for a below-floor energy stored vehicle includes a vehicle structural assembly having a front compartment section connected to a rear compartment section using first and second rocker members. The front compartment section includes a compartment front cross-beam and the rear compartment section includes a compartment rear cross-beam oriented parallel to the compartment front cross-beam. The vehicle structural assembly defines a bucket configuration having faces of the compartment front cross-beam and the compartment rear cross-beam angularly oriented from an upper outboard edge downwardly pitching to a lower inboard edge. A prefabricated sub-floor assembly seats on flange structure and is positioned with a clearance to the bucket configuration of the vehicle structural assembly. An outer perimeter of the sub-floor assembly is larger than an inner perimeter of the vehicle structural assembly where the sub-floor assembly contacts the vehicle structural assembly.

Abstract: An extruded rail assembly including a first multi-channel extrusion having at least two tubular channels connected by a center rib, and having a joining end configured for joining at a predetermined angle to a joining end of a second multi-channel extrusion. The second multi-channel extrusion includes at least two tubular channels connected by a center rib, and having a joining end configured for joining at the predetermined angle to the joining end of first multi-channel extrusion. The joining ends of the first and second multi-channel extrusions are configured such that the center ribs complementarily engage as a joining surface.

Abstract: One variation may include using a plurality of node structures to assemble a uniframe.

Abstract: A body panel that is attachable to a body structure is provided. The body panel has a single thickness portion and a double thickness edge portion where the body panel is hemmed over onto itself and is attachable to the body structure. The body panel may be made of a metal material or a non-metal material. The attachment may be via a weld, a fastener, and/or an adhesive.