Abstract: A chassis having systems responsive to a nonmechanical control signals and a simplified body-attachment interface includes preassembled modules to enhance ease and simplicity of chassis assembly. The chassis is preferably configured to minimize the possibility of a preassembled module being incorrectly positioned within the chassis. Methods for advantageously employing preassembled modules to assemble vehicle chassis are also provided.

Abstract: A method for assembling vehicular structural frames employing elongated members and connectors interconnecting the elongated members increases flexibility in assembling chassis frames and body frames. The method includes assembling a first vehicle structural frame according to a first design, and assembling a second vehicle structural frame according to a second design. The second design is derived from the first design by replacing elongated members of the first design with differently-dimensioned elongated members, or by changing the quantity of elongated members, to result in a second structural frame configuration different from the first structural frame configuration.

Abstract: A vehicle chassis includes a structural frame having a frame portion that partially defines an open space and that has a predetermined configuration such that the open space maintains a predetermined amount of spatial integrity in the event of a horizontal impact to the vehicle chassis. The frame also includes a frame component operatively connected to the frame portion that further defines the structural frame. The open space provides a protected packaging space wherein certain critical chassis components are placed. The frame portion configuration provides a pre-engineered protected area that may be used in a variety of structural frame configurations. Accordingly, a method for using pre-engineered frame portions is provided.

Abstract: A vehicle body compartment lid includes a unitary, one-piece panel. The panel has both an inner panel portion and an outer panel portion, and is bent or folded such that the inner panel portion and the outer panel portion are in juxtaposition with one another. A method of manufacturing a vehicle body compartment lid employing the panel is also provided. The panel is preferably formed using fluid pressure.

Abstract: Front structure for a vehicle includes a unitary panel formed to define a vehicle cowl and a vehicle bulkhead. The vehicle cowl may form an air intake plenum. The unitary panel is configured to at least partially define a front compartment of the vehicle. An alternative unitary panel is formed to define a hood having inner and outer panel portions and, optionally, fenders. Another alternative unitary panel is formed to define a cowl, a bulkhead and a hood. The preferable method for forming the panels is quick plastic forming, superplastic forming or sheet hydroforming.

Abstract: A vehicle floor includes a unitary, one-piece panel. The panel is formed with an integral channel for routing a vehicle distribution system conduit therewithin. The panel may include an inner panel portion, an outer panel portion, integral rocker panel portions, front, rear and trunk floor portions. A method is provided for manufacturing a vehicle floor, the method including forming such a panel.

Abstract: A distance measuring and display system for use on a vehicle having a mirror assembly thereon comprises at least one front distance measuring sensor for measuring the distance to an obstacle in front of the vehicle, at least one rear distance measuring sensor for measuring the distance to an obstacle to the rear of the vehicle, and a display coupled to the front distance measuring sensor and to the rear distance measuring sensor for displaying a distance and an indication of whether it is a front distance or a rear distance.

Abstract: A vehicle bumper is formed using fluid pressure such that the bumper is characterized by a curvature. The bumper preferably includes an upper bumper bar portion and a lower bumper bar portion that are interconnected. The bumper is also preferably connectable to a pair of upper rails and a pair of lower rails so that an impact load is distributable between the upper rails and the lower rails. The bumper preferably includes an inner panel and an outer panel. A method of forming a bumper is also provided. The method includes subjecting a metal blank to fluid pressure to form a bumper having a shape characterized by a curvature.

Abstract: A vehicle door includes an inner panel having strengthening corrugations to function as an impact beam, thereby negating the need for a separate impact beam. The inner panel is preferably characterized by a generally concave shape to increase vehicle interior space compared to prior art doors. A forming technique employing fluid pressure is preferably employed to form the inner panel.

Abstract: Various body configurations capitalize upon the interchangeability of vehicle bodies on a flat rolling chassis. The ability to interchange vehicle bodies and exchange modular interior components enables substantial freedom and variation in the types of automobile, trucks, heavy equipment, machinery, RV bodies, etc. that can be interchanged on a rolling chassis. Various seating arrangements may be provided as well as enhanced space utilization, and different types of interior and exterior environments, aesthetics and functionality, including sound, lighting, and other technology enhancements may be provided on a body. Methods and structures facilitate the exchange of modular body components, such as via a removable body floor.

Abstract: A body and frame assembly for a vehicle includes a one-piece inner member mated with a one-piece outer member, the inner member and the outer member defining door openings at opposing sides of the vehicle. The inner member and the outer member may each include a roof panel portion and two side frame portions. A method of assembling a vehicle that includes the body and frame assembly includes forming each of the inner and outer members by quick plastic forming, super plastic forming or hydroforming. Preferably, the inner member and the outer member are each formed from a separate single sheet of aluminum.

Abstract: A motorized cover system includes a cover movably connected with respect to a compartment such as a vehicle component, at least one motor vehicle, and at least one linkage operatively connecting the cover to the motor, wherein the motor is operable for moving the cover between a closed position and at least one open position. The motorized cover system may include an automatically engageable and disengageable latch assembly for securing the cover to the vehicle. A method of opening and closing a vehicle compartment cover includes relaying an operator control signal to a motor, powering the motor, and moving the cover between a first position and a second position.

Abstract: Various vehicle body business processes are described which capitalize upon the interchangeability of vehicle bodies on a flat rolling chassis. The ability to interchange vehicle bodies and exchange modular interior components enables substantial freedom and variation in the types of automobile, trucks, heavy equipment, machinery, RV bodies, etc. that can be interchanged on a rolling chassis. Various seating arrangements may be provided as well as enhanced space utilization, and different types of interior and exterior environments, aesthetics and functionality, including sound, lighting, and other technology enhancements may be provided on a body. Methods and structures are described for facilitating the exchange of modular body components, such as via a removable body floor.

Abstract: A method of assembling a vehicle chassis includes providing a vehicle frame having a plurality of packaging cavities opening in a plurality of different directions, mounting vehicle hardware components toward openings in the packaging cavities and installing the vehicle hardware components into operative positions in their packaging cavities. The installation of the vehicle hardware components and their respective packaging cavities may be arranged to make the components removable from the frame in respective ones of the different directions.

Abstract: A structural frame for a vehicle chassis includes transversely-oriented unitary structural members interconnecting at least three longitudinally-oriented elongated members. The use of unitary structural members and elongated members provides flexibility in assembling structural frames of differing configurations. Correspondingly, a method of assembling structural frames having transversely-oriented unitary structural members interconnecting at least three longitudinally-oriented elongated members is provided.

Abstract: An electrical distribution system for a vehicle having electrical devices includes at least one junction box and a plurality of terminals interconnected by at least one conductive path. The electrical distribution system operatively interconnects the electrical devices when the electrical devices are appropriately connected to the electrical distribution system via the terminals. A method for advantageously using an electrical distribution system having sufficient terminals and sufficient conductive paths to accommodate a plurality of vehicle electrical device combinations is also provided.

Abstract: A chassis subassembly module having a portion of a chassis structural frame and vehicular componentry facilitates the assembly of a chassis having systems responsive to non-mechanical control signals and a simplified body-attachment interface. A method of employing chassis subassembly modules to assemble chassis is also provided.

Abstract: A lower vehicle body structure for a vehicle body defining an interior space includes structural elements that extend higher than the lower extent of the interior space. The structural elements protect the spatial integrity of the interior space by being sufficiently configured and positioned to receive a load at a point higher than the lower extent of the interior space from an impact to the vehicle body. The vehicle body is configured to be matable with a chassis having systems that are responsive to nonmechanical control signals. A method for advantageously using pre-engineered lower body structures as a common base for bodies of varying styles, types, and configurations is also provided.

Abstract: A rear and side panel assembly for a vehicle body may include a one-piece inner body panel member mated with a one-piece outer body panel member, the body panels cooperating to at least partially define wheel well openings at opposing sides of the vehicle. The inner body panel member may include an inner rear panel portion with opposite ends, a first inner side panel portion at one end and a second inner side panel portion at the opposed end, with the inner side panel portions extending generally frontward from the inner rear panel portion. The outer body panel member may include an outer rear panel portion with opposite ends, a first outer side panel portion at one end and a second outer side panel portion at the opposed end, with the outer side panel portions extending generally frontward from the outer rear panel portion.

Abstract: Various body configurations capitalize upon the interchangeability of vehicle bodies on a flat rolling chassis. The ability to interchange vehicle bodies and exchange modular interior components enables substantial freedom and variation in the types of automobile, trucks, heavy equipment, machinery, RV bodies, etc. that can be interchanged on a rolling chassis. Various seating arrangements may be provided as well as enhanced space utilization, and different types of interior and exterior environments, aesthetics and functionality, including sound, lighting, and other technology enhancements may be provided on a body. Methods and structures facilitate the exchange of modular body components, such as via a removable body floor.