Abstract: A lightweight vehicle pan assembly and for attachment to a vehicle frame via welding includes at least one metal flange and a molded pan body. The at least one metal flange has a weld portion adapted for welded attachment to the vehicle frame and an interface portion extending from the weld portion. The molded pan body has a base wall and at least one side wall extending upward from the base wall. The interface portion of the at least one metal flange is embedded in the at least one side wall of the molded pan body. The interface portion includes at least two rows of apertures defined therein for increasing a bond strength between the at least one metal flange and the molded pan body.

Abstract: A seal inserted into a circular opening in a work piece from a first direction for sealing a component inserted into the circular opening from a second direction is disclosed. The seal body has a ring shape and includes an upper edge and a lower edge. An upper seal extends radially outward and downward from the upper edge of the seal body, a lower seal extends radially inward and upward from the lower edge of the seal body, and a clip secures the seal to the circular opening.

Abstract: A vehicle frame assembly includes a main frame part including a side sill extending in a longitudinal direction of the vehicle frame assembly. The side sill has a C-shaped cross-section with a top and bottom walls, an inboard sidewall interconnecting the top and bottom walls, and an open outboard sidewall. A rear frame part is secured to the main frame part and includes a rear frame member extending in the longitudinal direction. The rear frame member has a U-shaped cross-section with an inboard and outboard sidewalls, a bottom wall interconnecting the inboard and outboard sidewalls, and an open top wall. The inboard sidewall at a rearward end portion of the side sill includes a section bulging away from the open outboard sidewall in a lateral direction of the vehicle frame assembly, and the inboard sidewall of the rear frame member is secured to the bulging section of the side sill.

Abstract: A vehicle frame assembly includes a main frame part including a side sill extending in a longitudinal direction of the vehicle frame assembly. The side sill has a C-shaped cross-section with a top and bottom walls, an inboard sidewall interconnecting the top and bottom walls, and an open outboard sidewall. A rear frame part is secured to the main frame part and includes a rear frame member extending in the longitudinal direction. The rear frame member has a U-shaped cross-section with an inboard and outboard sidewalls, a bottom wall interconnecting the inboard and outboard sidewalls, and an open top wall. The inboard sidewall at a rearward end portion of the side sill includes a section bulging away from the open outboard sidewall in a lateral direction of the vehicle frame assembly, and the inboard sidewall of the rear frame member is secured to the bulging section of the side sill.

Abstract: A method of joining a first body made of a first material to a second body made of a second material is disclosed. The method includes the steps of placing an adhesive between the first body and second body, moving the first body toward and into contact with the second body with the adhesive between the first body and the second body, pre-curing the adhesive, and curing the first body and second body in an oven. Pre-curing may be done by induction curing along a bonding line, pre-curing adhesive in a low temperature oven, or using a two-part adhesive.

Abstract: A lightweight vehicle pan assembly and for attachment to a vehicle frame via welding includes at least one metal flange and a molded pan body. The at least one metal flange has a weld portion adapted for welded attachment to the vehicle frame and an interface portion extending from the weld portion. The molded pan body has a base wall and at least one side wall extending upward from the base wall. The interface portion of the at least one metal flange is embedded in the at least one side wall of the molded pan body. The interface portion includes at least two rows of apertures defined therein for increasing a bond strength between the at least one metal flange and the molded pan body.

Abstract: A seal inserted into a circular opening in a work piece from a first direction for sealing a component inserted into the circular opening from a second direction is disclosed. The seal body has a ring shape and includes an upper edge and a lower edge. An upper seal extends radially outward and downward from the upper edge of the seal body, a lower seal extends radially inward and upward from the lower edge of the seal body, and a clip secures the seal to the circular opening.

Abstract: A method of joining a first body made of a first material to a second body made of a second material is disclosed. The method includes the steps of placing an adhesive between the first body and second body, moving the first body toward and into contact with the second body with the adhesive between the first body and the second body, pre-curing the adhesive, and curing the first body and second body in an oven. Pre-curing may be done by induction curing along a bonding line, pre-curing adhesive in a low temperature oven, or using a two-part adhesive.

Abstract: A joint includes a first body, a second body, and an adhesive. The first body includes a coated portion and an uncoated portion. The second body includes a coated portion and an uncoated portion. The adhesive is positioned on the uncoated portion of each of the first and second bodies. The adhesive is expandable to cover at least a part of the coated portion of each of the first and second bodies. The first body and the second body can be fabricated for dissimilar materials. The adhesive includes insulating properties that can insulate the first body from the second body to inhibit galvanic corrosion. During a method of forming a joint between a first body and a second body, the adhesive can be at least partially cured so as to hold the first body and second body in the proper relative alignment during the formation process.

Abstract: A battery mounting assembly for a vehicle includes a battery tray configured to carry an associated vehicle battery and a battery tray support structure mounted to an underside of the vehicle. The battery tray is slidably mounted to the battery tray support structure for movement between a first operational position and a second maintenance position. The second maintenance position is laterally spaced apart from and below the first operational position.

Abstract: A frame assembly for a vehicle includes a subframe, a collar assembly with a collar member and a mounting pin, and a main frame with a saddle. The main frame has a contact side that faces toward the collar assembly and the saddle is located on the contact side. The subframe is connected to the main frame with a bolt that extends from the subframe and into a bore in the mounting pin. The mounting pin is in contact with the saddle.

Abstract: A battery mounting assembly for a vehicle includes a battery tray configured to carry an associated vehicle battery and a battery tray support structure mounted to an underside of the vehicle. The battery tray is slidably mounted to the battery tray support structure for movement between a first operational position and a second maintenance position. The second maintenance position is laterally spaced apart from and below the first operational position.

Abstract: A frame assembly for a vehicle includes a subframe, a collar assembly with a collar member and a mounting pin, and a main frame with a saddle. The main frame has a contact side that faces toward the collar assembly and the saddle is located on the contact side. The subframe is connected to the main frame with a bolt that extends from the subframe and into a bore in the mounting pin. The mounting pin is in contact with the saddle.

Abstract: A vehicle frame includes a pair of spaced frame rails and at least one cross member connecting the frame rails. A tower structure is on one of the spaced frame rails for supporting a floor of a load-carrying bed spaced above the frame rails.