Abstract: A frangible vehicle sub-frame joint between a sub-frame and compartment pan. The sub-frame defines a clearance area forward of a collar. In a collision event, the collar is separated into a breakaway portion and a portion that is retained by the sub-frame. The breakaway portion breaks into a clearance area defined in front of the frame joint when the sub-frame is subjected to a front end impact.

Abstract: A frangible vehicle sub-frame joint between a sub-frame and compartment pan. The sub-frame defines a clearance area forward of a collar. In a collision event, the collar is separated into a breakaway portion and a portion that is retained by the sub-frame. The breakaway portion breaks into a clearance area defined in front of the frame joint when the sub-frame is subjected to a front end impact.

Abstract: A structure for transferring energy during an automotive front end impact includes an upper load path structure having a first shotgun rail a second shotgun rail and an upper radiator bar extending therebetween, a lower load path structure having a first side rail a second side rail and a lower support member extending therebetween. During an impact, the upper radiator bar is configured to transfer energy to the first and second shotgun rails, and the lower support member is configured to transfer energy to the first and second side rails during an impact.

Abstract: A structure for transferring energy during an automotive front end impact includes an upper load path structure having a first shotgun rail a second shotgun rail and an upper radiator bar extending therebetween, a lower load path structure having a first side rail a second side rail and a lower support member extending therebetween. During an impact, the upper radiator bar is configured to transfer energy to the first and second shotgun rails, and the lower support member is configured to transfer energy to the first and second side rails during an impact.

Abstract: A pillar to rocker joint assembly comprising a tubular pillar having a pinched flange near a lower end of the pillar is joined to a rocker assembly including a side sill and rocker reinforcement. A method of making a pillar to rocker joint assembly that comprises a vehicle structural support is formed by welding a structural support pillar to an outer body panel through an access opening in the pillar and welding a rocker reinforcement to a side sill. The rocker reinforcement is welded to the pillar through an access opening in the side sill, an access hole in the body outer panel, and an access opening in the pillar that is vertically spaced relative to the first access opening. A bottom flange of the B-pillar is welded to a lower edge flange of the rocker reinforcement and a lower edge flange of the side sill.

Abstract: A pillar to rocker joint assembly comprising a tubular pillar having a pinched flange near a lower end of the pillar is joined to a rocker assembly including a side sill and rocker reinforcement. A method of making a pillar to rocker joint assembly that comprises a vehicle structural support is formed by welding a structural support pillar to an outer body panel through an access opening in the pillar and welding a rocker reinforcement to a side sill. The rocker reinforcement is welded to the pillar through an access opening in the side sill, an access hole in the body outer panel, and an access opening in the pillar that is vertically spaced relative to the first access opening. A bottom flange of the B-pillar is welded to a lower edge flange of the rocker reinforcement and a lower edge flange of the side sill.

Abstract: A dual function mounting bracket is affixed to a hydroformed roof side rail to allow the connecting brackets to be located at the same position as previously known despite the use of a hydroformed roof side rail frame member that has a substantially different shape and configuration. The dual function mounting bracket has a first mounting surface projecting upwardly from a second mounting surface to provide support for a grab handle connecting bracket. The second mounting surface provides support for the connecting bracket of a side curtain air bag. The second mounting surface is also configured with a pair of side tabs and a front tab for welding the mounting bracket to a hydroformed roof side rail. The grab handle spans between the mounting bracket and a spaced apart sole function mounting bracket. A bead between the first and second mounting surfaces on the dual function mounting bracket provides stiffness.

Abstract: A support rail for a vehicle has an A-pillar portion and a roof rail portion. The roof rail and A-pillar are formed with a tubular body portion and longitudinally extending support flanges. The support flanges are formed by pinching the blank during the hydroforming process to provide a double thickness flange. A windshield support flange, roof support flange and door opening flange are formed to extend outwardly from the tubular body portion. Front and rear tube connectors include blind openings or notches to facilitate welding.

Abstract: A dual function mounting bracket is affixed to a hydroformed roof side rail to allow the connecting brackets to be located at the same position as previously known despite the use of a hydroformed roof side rail frame member that has a substantially different shape and configuration. The dual function mounting bracket has a first mounting surface projecting upwardly from a second mounting surface to provide support for a grab handle connecting bracket. The second mounting surface provides support for the connecting bracket of a side curtain air bag. The second mounting surface is also configured with a pair of side tabs and a front tab for welding the mounting bracket to a hydroformed roof side rail. The grab handle spans between the mounting bracket and a spaced apart sole function mounting bracket. A bead between the first and second mounting surfaces on the dual function mounting bracket provides stiffness.

Abstract: A joint assembly for joining a tubular B-pillar to a tubular roof rail. The joint assembly includes an inner bracket plate and an outer bracket plate that are welded to each other around the roof rail and B-pillar. The outer bracket plate extends across the B-pillar, over the roof rail, and laterally inwardly from the roof rail to provide an attachment surface for a roof support bow.

Abstract: A pillar to rocker joint assembly comprising a tubular pillar having a pinched flange near a lower end of the pillar is joined to a rocker assembly including a side sill and rocker reinforcement. A method of making a pillar to rocker joint assembly that comprises a vehicle structural support is formed by welding a structural support pillar to an outer body panel through an access opening in the pillar and welding a rocker reinforcement to a side sill. The rocker reinforcement is welded to the pillar through an access opening in the side sill, an access hole in the body outer panel, and an access opening in the pillar that is vertically spaced relative to the first access opening. A bottom flange of the B-pillar is welded to a lower edge flange of the rocker reinforcement and a lower edge flange of the side sill.

Abstract: A support rail for a vehicle is disclosed that has an A-pillar portion and a roof rail portion. The roof rail and A-pillar are formed with a tubular body portion and longitudinally extending support flanges. The support flanges are formed by pinching the blank during the hydroforming process to provide a double thickness flange. A windshield support flange, roof support flange and door opening flange are formed to extend outwardly from the tubular body portion. Front and rear tube connectors may be provided that include blind openings or notches to facilitate welding.

Abstract: A one-piece B-pillar having a front flange and a rear flange formed on an upper portion of the B-pillar. The front and rear flanges extend forwardly and rearwardly from a trapezoidal section of the B-pillar. An inner concave portion is provided in a lower portion of the B-pillar. The one-piece B-pillar is secured to the outer and upper surfaces of a roof rail and to the outer surface of a rocker to provide side impact strength. The B-pillar is hydroformed in one-piece to provide superior strength for roof crush performance. The tubular portion of the B-pillar is partially collapsed to form a trapezoidal section in the upper portion of the B-pillar.

Abstract: A joint assembly for joining a tubular B-pillar to a tubular roof rail. The joint assembly includes an inner bracket plate and an outer bracket plate that are welded to each other around the roof rail and B-pillar. The outer bracket plate extends across the B-pillar, over the roof rail, and laterally inwardly from the roof rail to provide an attachment surface for a roof support bow.

Abstract: A joint assembly for joining a tubular B-pillar to a tubular roof rail. The joint assembly includes an inner bracket plate and an outer bracket plate that are welded to each other around the roof rail and B-pillar. A flange of the roof rail is received in a slot formed in an upper end of the B-pillar.

Abstract: A joint assembly for joining a tubular B-pillar to a tubular roof rail. The joint assembly includes an inner bracket plate and an outer bracket plate that are welded to each other around the roof rail and B-pillar. A flange of the roof rail is received in a slot formed in an upper end of the B-pillar.

Abstract: A one-piece B-pillar having a front flange and a rear flange formed on an upper portion of the B-pillar. The front and rear flanges extend forwardly and rearwardly from a trapezoidal section of the B-pillar. An inner concave portion is provided in a lower portion of the B-pillar. The one-piece B-pillar is secured to the outer and upper surfaces of a roof rail and to the outer surface of a rocker to provide side impact strength. The B-pillar is hydroformed in one-piece to provide superior strength for roof crush performance. The tubular portion of the B-pillar is partially collapsed to form a trapezoidal section in the upper portion of the B-pillar.