Abstract: A structural assembly for a vehicle that includes a cast main body, a left apron, a right apron, a left mounting feature, a right mounting feature, a left strut cap, and a right strut cap. The left apron is fixed to a left upper rail and defines a first opening extending therethrough. The right apron is fixed to a right upper rail and defines a second opening extending therethrough. The left mounting feature extends at least partially around a first periphery of the first opening. The right mounting feature extends at least partially around a second periphery of the second opening. The left strut cap is secured to the left mounting feature such that the left strut cap covers the first opening. The right strut cap is secured to the right mounting feature such that the right strut cap covers the second opening.

Abstract: The battery structure for an electric vehicle includes battery arrays. A first battery array includes first walls that are secured to each other to form a first unitized structure that is configured to house a first cell stack. One first wall of the first walls includes a first vertical portion, a first upper portion, and a first lower portion. A second battery array includes second walls that are secured to each other to form a second unitized structure that is configured to house a second cell stack. One second wall of the second walls includes a second vertical portion and a second upper portion. The second vertical portion is spaced apart from the first vertical portion. The second upper portion extends toward the first vertical portion from an upper end of the second vertical portion and is secured to the first upper portion of the first battery array.

Abstract: A battery pack includes an upper sidewall section of an enclosure, a lower sidewall section of the enclosure, and a fastener that moves to a secured position to secure the upper sidewall section to the lower sidewall section. The fastener is configured to be moved to the secured position from within an interior area of the enclosure. The battery pack further includes a gasket seal held between the upper sidewall section and the lower sidewall section at a position outside the fastener relative to an interior area of the enclosure.

Abstract: A single monolithic body extends in a longitudinal direction and includes multiple closed sections stacked vertically. A first end portion of the single monolithic body extends from one of the closed sections into an adjacent closed section, and a second end portion of the single monolithic body extends from one of the closed sections, along an exterior of an adjacent closed section, and laterally away from the single monolithic body to form a connecting flange.

Abstract: Vehicle subframes and methods of producing the same are disclosed. An example apparatus includes a subframe of a vehicle including longitudinal members, and lateral extensions extending from the longitudinal members, the lateral extensions extending outward from a longitudinal centerline of the vehicle, outer edges of the lateral extensions including contours to avoid turn radii of steerable tires of the vehicle.

Abstract: A structural assembly for a vehicle includes a vehicle frame distinct from a vehicle body. The vehicle frame includes opposed longitudinal rails. Each rail includes a single, monolithic body having a central internal brace and a pair of opposed ends. One end of the opposed ends is fixed to a first side of the central internal brace and the other end of the opposed ends is fixed to a second side of the central internal brace that is opposite the first side.

Abstract: A battery mounting structure includes a shear plate and a plurality of separate reinforcement plates. The shear plate extends in a longitudinal direction of the vehicle and includes a first thickness. The reinforcement plates are configured to be disposed between the shear plate and the battery housing assembly and are mounted on an upper surface of the shear plate. The reinforcement plates are spaced apart from each other and include a second thickness. The second thickness is greater than the first thickness.

Abstract: Vehicle subframes and methods of producing the same are disclosed. An example apparatus includes a subframe of a vehicle including longitudinal members, and lateral extensions extending from the longitudinal members, the lateral extensions extending outward from a longitudinal centerline of the vehicle, outer edges of the lateral extensions including contours to avoid turn radii of steerable tires of the vehicle.

Abstract: A structural assembly for a vehicle includes a battery structure having a battery frame. The structural assembly includes a vehicle frame and a vehicle body. The vehicle frame has opposed longitudinal rails. The vehicle body is separate from and mounted on the vehicle frame. The vehicle body includes opposed rockers extending in a longitudinal direction of the vehicle. Each opposed longitudinal rail is located between a respective rocker and the battery frame of the battery structure.

Abstract: Exemplary traction battery pack designs are disclosed for use in electrified vehicles. An exemplary traction battery pack may include an outer enclosure assembly that may house one or more battery arrays and/or other battery internal components. The outer enclosure assembly may include a tray having a mixed material or “hybrid” structure that provides a space efficient design. The tray may include a first subassembly made of a first material and a second subassembly made of a second, different material. The first subassembly may include a tub, and the second subassembly may include a heat exchanger plate. Central and perimeter joint strategies may be employed for securing the second subassembly relative to the first subassembly to provide the space efficient design.

Abstract: This disclosure relates to a projection for a vehicle frame rail and a corresponding method. In some aspects, the techniques described herein relate to a vehicle, including: a frame rail; and a projection extending laterally outward from a laterally outer surface of the frame rail, wherein the projection is a part of a running board assembly.

Abstract: A traction battery pack assembly includes a cell stack disposed along a cell stack axis. A sheet metal enclosure structure holds the cell stack within a cell-receiving area and compresses the cell stack along the cell stack axis. A battery pack assembly method includes forming a sheet metal blank into an enclosure structure having a cell-receiving area, inserting a cell stack into the cell-receiving area of the enclosure structure, and, after the inserting, compressing the cell stack with the enclosure structure.

Abstract: Shock absorber assembly structures are disclosed. An example shock absorber disclosed herein includes a shock absorber mount coupled to an end of the shock absorber, the shock absorber mount including a recess to receive a locating rib of a vehicle body, and an aperture to receive a fastener to couple the shock absorber mount to an attachment boss of the vehicle body.

Abstract: A vehicle includes a vehicle frame. The vehicle frame includes a frame rail elongated along a vehicle-longitudinal axis that defines a hole. The vehicle includes a trailer hitch mount supported by the frame rail. The vehicle includes a face plate supported by the trailer hitch mount that defines an opening extending through the face plate that is aligned with the hole of the frame rail. The trailer hitch mount extends through the opening and is completely surrounded by the face plate. The trailer hitch mount extends into the hole of the frame rail along the vehicle-longitudinal axis.

Abstract: A battery pack includes an upper sidewall section of an enclosure, a lower sidewall section of the enclosure, and a fastener that moves to a secured position to secure the upper sidewall section to the lower sidewall section. The fastener is configured to be moved to the secured position from within an interior area of the enclosure. The battery pack further includes a gasket seal held between the upper sidewall section and the lower sidewall section at a position outside the fastener relative to an interior area of the enclosure.

Abstract: A structural assembly for a vehicle includes a battery structure having a battery frame. The structural assembly includes a vehicle frame and a vehicle body. The vehicle frame has opposed longitudinal rails. The vehicle body is separate from and mounted on the vehicle frame. The vehicle body includes opposed rockers extending in a longitudinal direction of the vehicle. Each opposed longitudinal rail is located between a respective rocker and the battery frame of the battery structure.

Abstract: The present disclosure relates to a rail assembly that includes an outer rail and an inner rail opposite to the outer rail. The rail assembly also includes a cavity formed between the outer rail and the inner rail. The rail assembly further includes a first corner reinforcement coupled to the outer rail and the inner rail in such a way that at least a portion of the first corner reinforcement is located in the cavity. The rail assembly also includes a second corner reinforcement coupled to the outer rail and the inner rail in such a way that at least a portion of the first corner reinforcement is located in the cavity.

Abstract: A vehicle assembly includes a first component having a stand-off that provides a cavity. The stand-off protrudes from an insertion side of the first component. The stand-off includes at least one side wall that extends from a floor of the cavity to at least one outer surface of the stand-off. The assembly further includes a second component that contacts the first component at an interface. The cavity is configured to receive a mechanical fastener that joins the first component to the second component. A distance between the floor of the cavity and the interface is greater in some areas than in other areas such that a cross-sectional thickness at a bottom of the cavity is varied.

Abstract: The present disclosure is directed to extrusion for a vehicle component. The vehicle component includes a plurality of flanges that form a periphery of the vehicle component, a cavity that extends through the periphery of the vehicle component, a corner portion that is positioned proximate to a corner defined by a pair of the plurality of flanges, and a channel that is positioned proximate to the corner portion.

Abstract: Shock absorber assembly structures are disclosed. An example shock absorber disclosed herein includes a shock absorber mount coupled to an end of the shock absorber, the shock absorber mount including a recess to receive a locating rib of a vehicle body, and an aperture to receive a fastener to couple the shock absorber mount to an attachment boss of the vehicle body.