Abstract: A vehicle body structure includes a system of connected unitized body structure components, with at least one of the system of connected unitized body structure components including a hollow portion.

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: An assembly includes a first component having a first threaded opening therein, and a second component having a second component opening therethrough. A bolt assembly secures the second component relative to the first component. The bolt assembly includes a first bolt having a spacer portion and a first threaded shaft extending from the spacer portion to engage the first threaded opening. The first bolt includes an internal thread extending axially from the spacer portion. The bolt assembly further includes a second bolt having a head and a second threaded shaft extending from the head. The second threaded shaft extends through the second component opening to engage the internal thread of the first bolt to secure the second component relative to the first component.

Abstract: A vehicle body structure includes a system of connected unitized body structure components, with at least one of the system of connected unitized body structure components including a hollow portion.

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: An assembly includes a first component having a first threaded opening therein, and a second component having a second component opening therethrough. A bolt assembly secures the second component relative to the first component. The bolt assembly includes a first bolt having a spacer portion and a first threaded shaft extending from the spacer portion to engage the first threaded opening. The first bolt includes an internal thread extending axially from the spacer portion. The bolt assembly further includes a second bolt having a head and a second threaded shaft extending from the head. The second threaded shaft extends through the second component opening to engage the internal thread of the first bolt to secure the second component relative to the first component.

Abstract: A structural load path assembly includes an upper rail configured to be coupled to a suspension system, a lower rail spaced apart from the upper rail along a vertical direction, a first outer bracket interconnecting the upper rail and the lower rail, a second outer bracket interconnecting the upper rail and the lower rail, a first inner bracket interconnecting the upper rail and the lower rail, wherein the first inner bracket is spaced apart from the first outer bracket along a horizontal direction, and the horizontal direction is perpendicular to the vertical direction, a second inner bracket interconnecting the upper rail and the lower, and a box section sized to receive a shock absorber.

Abstract: A structural load path assembly includes an upper rail configured to be coupled to a suspension system, a lower rail spaced apart from the upper rail along a vertical direction, a first outer bracket interconnecting the upper rail and the lower rail, a second outer bracket interconnecting the upper rail and the lower rail, a first inner bracket interconnecting the upper rail and the lower rail, wherein the first inner bracket is spaced apart from the first outer bracket along a horizontal direction, and the horizontal direction is perpendicular to the vertical direction, a second inner bracket interconnecting the upper rail and the lower, and a box section sized to receive a shock absorber.

Abstract: A body structure for an automotive vehicle includes an enclosure for a power source, an upper shear structure assembly and a lower shear structure assembly. The enclosure includes a front cross-member, a rear cross-member, a left rocker and a right rocker. The upper and lower shear structure assemblies are disposed across the top and bottom of the enclosure, respectively, and are fastened to respective top and bottom surfaces of the cross-members and rockers. The upper and lower shear structure assemblies may include respective front and rear generally trapezoidal sections configured for attachment to respective front and rear box structures. Each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.

Abstract: A barrier assembly for an energy storage system includes a panel and an energy storage pack. The panel includes an outer surface and an inner surface opposing the outer surface. The energy storage pack is spaced from the panel relative to the inner surface of the panel. The barrier assembly further includes an intermediate structure disposed between the inner surface of the panel and the energy storage pack. The intermediate structure is configured to absorb energy when a load is applied to the outer surface of the panel and configured to redistribute the load along a plurality of load paths through the intermediate structure as the load is applied to the panel. A vehicle includes the barrier assembly discussed above. The vehicle includes a support structure and the barrier assembly is coupled to the support structure. The inner surface of the panel faces toward the support structure.

Abstract: A structural arrangement for a vehicle includes a body structure defining a longitudinal vehicle body axis and a lateral vehicle axis orthogonal to the longitudinal vehicle body axis. The body structure includes a lattice shear structure having a first structural member extending laterally from one side to an opposite side of the vehicle and a second structural member parallel to and longitudinally spaced apart from the first structural member, an upper shear panel extending longitudinally and laterally across the vehicle and joined to the lattice shear structure, and a seat attachment structure having a first end and a second end opposite the second end. The seat attachment structure is oriented longitudinally and is joined to both of the first and second structural members.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

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 barrier assembly for an energy storage system includes a panel and an energy storage pack. The panel includes an outer surface and an inner surface opposing the outer surface. The energy storage pack is spaced from the panel relative to the inner surface of the panel. The barrier assembly further includes an intermediate structure disposed between the inner surface of the panel and the energy storage pack. The intermediate structure is configured to absorb energy when a load is applied to the outer surface of the panel and configured to redistribute the load along a plurality of load paths through the intermediate structure as the load is applied to the panel. A vehicle includes the barrier assembly discussed above. The vehicle includes a support structure and the barrier assembly is coupled to the support structure. The inner surface of the panel faces toward the support structure.

Abstract: A structural arrangement for a vehicle includes a body structure defining a longitudinal vehicle body axis and a lateral vehicle axis orthogonal to the longitudinal vehicle body axis. The body structure includes a lattice shear structure having a first structural member extending laterally from one side to an opposite side of the vehicle and a second structural member parallel to and longitudinally spaced apart from the first structural member, an upper shear panel extending longitudinally and laterally across the vehicle and joined to the lattice shear structure, and a seat attachment structure having a first end and a second end opposite the second end. The seat attachment structure is oriented longitudinally and is joined to both of the first and second structural members.

Abstract: A body structure for an automotive vehicle includes an enclosure for a power source, an upper shear structure assembly and a lower shear structure assembly. The enclosure includes a front cross-member, a rear cross-member, a left rocker and a right rocker. The upper and lower shear structure assemblies are disposed across the top and bottom of the enclosure, respectively, and are fastened to respective top and bottom surfaces of the cross-members and rockers. The upper and lower shear structure assemblies may include respective front and rear generally trapezoidal sections configured for attachment to respective front and rear box structures. Each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.

Abstract: A connection member includes a first side and a second side opposite the first side. The connection member also includes a third side connecting the first and second sides, the third side including a first portion, a second portion, and a third portion, a first edge separating the first portion from the second portion and a second edge separating the second portion from the third portion. A first flange extends along the first edge and a second flange extends along the second edge such that the first and second flanges are separated by the second portion.

Abstract: An automotive vehicle includes a vehicle body with a longitudinal axis. The vehicle also includes a rocker inner panel with a first channel having interior and exterior sides. The interior side is secured to the vehicle body. The first channel has a first upper horizontal sidewall, a first lower horizontal sidewall, and a first vertical endwall coupling the first upper and first lower horizontal sidewalls at the interior side. A rocker outer panel is secured to the rocker inner panel. The rocker outer panel includes a second channel, a third channel, and a fourth channel. The second channel is secured to the third channel, and the third channel is secured to the fourth channel. An upper cavity is defined between the second and third channels, an intermediate cavity is defined between the third and fourth channels, and a lower cavity is defined between the second and third channels.

Abstract: An energy absorbing structure for a vehicle includes a body having an outer periphery defined by one or more outer walls. An inner periphery of the body is defined by and extends between the one or more outer walls. A first end and a second end of the body are defined by the one or more outer walls. A transverse plate is disposed within and extending at least partially through the inner periphery of the body to provide structural support to the body, wherein the transverse plate cooperates with and extends between the first wall and the opposing second wall. The transverse plate divides the inner periphery into a first compartment defined between the third wall and the transverse plate and a second compartment defined between the fourth wall and the transverse plate.

Abstract: A connection member includes a first side and a second side opposite the first side. The connection member also includes a third side connecting the first and second sides, the third side including a first portion, a second portion, and a third portion, a first edge separating the first portion from the second portion and a second edge separating the second portion from the third portion. A first flange extends along the first edge and a second flange extends along the second edge such that the first and second flanges are separated by the second portion.