Abstract: An energy absorbing extruded bumper for a vehicle is disclosed. The extruded bumper is formed from a lightweight metal, preferably aluminum base alloy material. The extruded bumper includes an outer wall, an inner wall, a top wall connecting the outer and inner walls, and a bottom wall connecting the outer and inner walls. Extending between the outer and inner walls are two or more s-curved trigger stiffeners. The trigger stiffeners include an upper s-curved trigger stiffener connecting the outer and inner walls and a lower s-curved trigger stiffener connecting the outer and inner walls. The lower s-curved trigger stiffener is spaced apart from the upper s-curved trigger stiffener.

Abstract: A vehicle body structure having improved roof support characteristics is provided. The structure includes a roof rail integral to an A-pillar and a support pillar. The structure further includes a cross member. The A-pillar includes an inner surface, an outer surface, and a wall therebetween. The roof rail extends downwardly at a front end of the roof rail and extends downwardly at a rear end of the roof rail. The roof rail is integral to a one piece hollow A-pillar at the front end of the roof rail. The support pillar also includes an inner surface, an outer surface, and a wall therebetween. The support pillar also includes a tubular lower section that extends upwardly from the rocker. The upper section of the support pillar is integral to the rear end of the roof rail.

Abstract: A frame rail for a vehicle that is provided between vehicle frame and the bumper of a vehicle that has a thickness that varies from the front end of the rail to the back end of the rail. The compressive strength of the rail increases from the front end of the rail to the back end of the rail. The rail is rectangular in shape and the thickness of the rail is continuously increased to improve progressive crush characteristics of the rail under an oblique loading. A rail may be provided by providing a tubular rail having a plurality of ring shaped segments that have incrementally increasing thickness. Alternatively, the rail may have a uniformly increasing thickness from the front end to the back end.

Abstract: A structural joint configuration is formed in an automotive frame in which the frame members are bent into an angular orientation and joined together to form a structural joint in the automotive frame in which loads imposed on any of the frame members forming the joint will be transferred to and shared with the other frame members in the joint. The structural joint can be configured with as many legs as needed to conform to the number of frame members entering the joint. The frame members can be formed with any cross-sectional shape and from any conventional material or combination of materials. Joining the frame members at the structural joint can be accomplished by welding or by applying adhesives. Load distribution through the frame members forming the structural joint enables the joint to withstand an application of high loads without major cracks or bending at the structural joint.

Abstract: A frame rail for a vehicle that is provided between vehicle frame and the bumper of a vehicle that has a thickness that varies from the front end of the rail to the back end of the rail. The compressive strength of the rail increases from the front end of the rail to the back end of the rail. The rail is rectangular in shape and the thickness of the rail is continuously increased to improve progressive crush characteristics of the rail under an oblique loading. A rail may be provided by providing a tubular rail having a plurality of ring shaped segments that have incrementally increasing thickness. Alternatively, the rail may have a uniformly increasing thickness from the front end to the back end.

Abstract: A structural joint configuration is formed in an automotive frame in which the frame members are bent into an angular orientation and joined together to form a structural joint in the automotive frame in which loads imposed on any of the frame members forming the joint will be transferred to and shared with the other frame members in the joint. The structural joint can be configured with as many legs as needed to conform to the number of frame members entering the joint. The frame members can be formed with any cross-sectional shape and from any conventional material or combination of materials. Joining the frame members at the structural joint can be accomplished by welding or by applying adhesives. Load distribution through the frame members forming the structural joint enables the joint to withstand an application of high loads without major cracks or bending at the structural joint.