Abstract: A body panel includes a hood portion configured to extend over and across a vehicle front compartment, and two fender portions. A unitary, one-piece inner panel and a unitary, one-piece outer panel cooperate to define the hood portion and the two fender portions. The inner panel and the outer panel comprise a substantial portion of a vehicle body front end, replacing the multitude of inner panels, outer panels, and reinforcements in a prior art vehicle body. The body panel preferably functions as a load-bearing vehicle frame portion, reducing or eliminating prior art vehicle frame components. A method of manufacturing the body panel includes forming an inner panel and an outer panel using superplastic forming, quick plastic forming, or sheet hydroforming, and connecting the inner panel and the outer panel.

Abstract: A vehicle door 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 at least partially define a cavity therebetween. Door hardware can be operatively connected to the panel before the panel is bent or folded, thus providing a door assembler with unhindered access to the hardware mounting surfaces. A method of manufacturing a vehicle door employing the panel is also provided.

Abstract: A vehicle door includes various features that enable a thin door profile not achievable with the prior art. The vehicle door includes an inner panel, an outer panel, and a reinforcement member between the inner panel and the outer panel. Door hardware, including at least a window regulator, is connected to the reinforcement member such that the door hardware is outboard of a window, thereby enabling the inner panel to be positioned in close proximity to the window.

Abstract: A vehicle door includes various features that enable a thin door profile not achievable with the prior art. The vehicle door includes an inner panel, an outer panel, and a reinforcement member between the inner panel and the outer panel. Door hardware, including at least a window regulator, is connected to the reinforcement member such that the door hardware is outboard of a window, thereby enabling the inner panel to be positioned in close proximity to the window.

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 method of assembling vehicles includes providing an X-by-wire chassis and mounting a vehicle body at an upper face of the chassis. The vehicle body includes a body frame, a seating apparatus and one or more body panels, and may include a floor. The vehicle body may include one or more preassembled body modules. The invention contemplates that the body may be operatively connected to the chassis when it is mounted at the upper face of the chassis so that one or more of the systems in the chassis that are responsive to non-mechanical control signals will respond to such signals.

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: 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 panel functions as a hood by at least partially concealing an engine compartment, and functions as a structural load-bearing portion of a vehicle frame by structurally interconnecting vehicle frame members. The body panel preferably includes a hood portion and two fender portions.

Abstract: A vehicle chassis having substantially all of the mechanical, electrical, and structural componentry necessary for a fully functional vehicle, including at least an energy conversion system, a steering system, and a braking system. The chassis is characterized by a simplified attachment interface at which a vehicle body is matable with the chassis.

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 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 maintenance system predicts potential failure of a component or system using statistical data and methods. The maintenance system preferably includes a communications apparatus for communicating component or system performance data to an offboard network or data collection device. Methods for advantageously using the collected performance data are also provided.

Abstract: A vehicle is provided with an external mirror which is, in turn, equipped with a defroster. Means are provided for displaying a visual indication on the mirror when the defroster is activated. When a driver operates a manual switch within the vehicle, current is supplied from the vehicle's source of potential to the defroster and to the display means causing it to display an appropriate symbol or symbols.

Abstract: A distance measuring and display system displays, on the rear windshield of a vehicle, a representation of the distance between the rear end of the vehicle and an obstacle behind the vehicle. Distance measuring equipment, including at least one sensor on the rear of the vehicle, measures the distance which is then displayed.

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 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 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: 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 vehicle chassis having substantially all of the mechanical, electrical, and structural componentry necessary for a fully functional vehicle, including at least an energy conversion system, a steering system, and a braking system. The chassis is configured for matability with a variety of different types or styles of vehicle bodies. Various prior art mechanical control linkages between a driver and controlled systems are replaced with non-mechanical control signal transmission components. Fuel cell technology is also implemented.