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 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 includes a floorpan and a front seat having a lower seat portion and a substantially upright seatback portion. The lower seat portion is rigidly fixed with respect to the floorpan such that it is not movable fore or aft by an occupant of the seat. The vehicle body preferably includes a drive-by-wire control input device movable with respect to the front seat. The vehicle body is also preferably characterized by the absence of an engine compartment forward of a passenger compartment.

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 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: 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 vehicle seat includes a lower seat portion and a back portion. The lower seat portion and the back portion are formed from at least one panel by a method selected from the group consisting of quick plastic forming, superplastic forming and sheet hydroforming. The lower seat portion and the back portion are cooperatively configured to form a seat frame. Preferably, the lower seat portion includes a lower seat bottom panel portion and a matable lower seat top panel portion and the back portion includes a back bottom panel portion and a matable back top panel portion. The lower seat bottom panel portion, lower seat top panel portion, back bottom panel portion, and back top panel portion are preferably formed from a unitary, one-piece panel. A method of manufacturing a vehicle seat is provided.

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: 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 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 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: 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: 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.