Abstract: The apparatus of the present invention provides an improved pulley assembly. The pulley assembly includes a ring portion having a frictional surface and a radially inner ring flange defining a plurality of ring teeth. The pulley assembly also includes a hub integrally formed onto the ring portion. The hub has a peripheral hub flange that includes a top portion and a bottom portion configured to trap the ring flange therebetween. The hub flange is also configured to engage the ring teeth and thereby prevent rotation of the hub relative to the ring portion. The ring portion is preferably composed of a first material such as steel or cast iron, and the hub is preferably composed of a second material such as aluminum or magnesium that is lighter by volume than the first material. Accordingly, the overall weight of the pulley assembly is less than that of a comparable pulley assembly composed entirely of steel or cast iron.

Abstract: The apparatus of the present invention provides a brake rotor assembly. The brake rotor assembly includes a generally annular rotor having a frictional surface and a radially inner rotor flange defining a plurality of rotor teeth. The brake rotor assembly also includes a hub section integrally formed onto the rotor. The hub section has a peripheral hub flange configured to engage the plurality of rotor teeth and thereby prevent rotation of the hub section relative to the rotor. The rotor is preferably composed of a first material such as steel or cast iron, and the hub section is preferably composed of a second material such as aluminum or magnesium that is lighter by volume than the first material. Accordingly, the overall weight of the rotor assembly is less than that of a comparable rotor assembly composed entirely of steel or cast iron.

Abstract: A vehicle includes a body defining an engine compartment and a plurality of vehicle frame members. An engine compartment cover defines a portion of the engine compartment and functions as a structural load-bearing portion of a vehicle frame by rigidly, structurally interconnecting vehicle frame members.

Abstract: A stack of sheet metal elements, formed and/or informed, is aligned and compressed so that the edges of the sheet elements form sides of the stack. The edges and intervening interfacial gaps are sealed with molten solder. The practice is particularly applicable to a stack of electrode, current collector and fluid conduit elements for an on-board vehicle fuel cell. The edges of the compressed metal elements are coated and sealed with solder to prevent incursion of contaminants from the vehicle environment and to retain fuel cell fluids.

Abstract: Apparatus for hot gas blow-forming including opposed heated and insulated tool containers, each including a tool heater plate that is adapted for attachment to a platen of a press with one or more load bearing spacers interposed between the tool heater plate and the platen. Each tool container also includes an insulation enclosure having a base portion that is interposed between the tool heater plate and the platen and further having perimeter wall portion that surrounds the tool heater plate. A perimeter seal is preferably attached to at least one of the heated and insulated tool containers and is adapted for sealing engagement with the other of the heated and insulated tool containers.

Abstract: A two-piece side frame comprising a one-piece inner panel and a one-piece outer panel that are operatively connected to one another and extending substantially longitudinally at least the entire length of the vehicle passenger compartment. Consolidations of upper body structures such as front cowl beam, front structure, front tie bar assembly, roof and rear package shelf, and the rear structure of a vehicle using fluid forming processes are provided. A method of producing the two-piece side frame as well as a B pillar and cowl beam by utilizing fluid forming techniques is provided.

Abstract: An integrally designed roof rack and roof panel attached to a vehicle may be formed using quick plastic forming (QPF) and superplastic forming processing (SPF). A number of vehicle accessories such as luggage containers, fuel tanks, consoles, door attachments, truck beds and table trays may be formed using QPF processes. The items may be installed and movable onto and off the vehicle. A variety of QPF processes may be employed, enabling the vehicle accessory to meet required strength, dimensional, and shape considerations. Additionally, component integration is enabled by using QPF processes.

Abstract: A lower body component of a vehicle having a one-piece floor pan extending substantially longitudinally at least the entire length of the vehicle passenger compartment. The one piece floor pan may be reinforced with a one piece reinforcement structural member, formed to at least partially define a seat mounting beam and a tunnel portion of the vehicle. A method of producing a one-piece floor pan and a one-piece reinforcement structural member by utilizing fluid forming techniques such as quick plastic forming, superplastic forming and sheet hydroforming and adjunct techniques is provided.