Abstract: A reinforced structural member has a w-shaped reinforcement member that carries a thermally expandable resin-based material. The w-shaped reinforcement member is placed in the channel of a hollow structural member over a transverse pin which fits through the slot of the reinforcement member. The structural member is heated to expand the resin-based material which locks the reinforcement member in place, thereby significantly strengthening the structural member.

Abstract: A teardrop shaped vehicle body which elevates from front to rear thereby providing a safe and aerodynamic shape on which two front wheels and a single rear wheel are rotatably mounted. The vehicle body includes a frame over which flat sheets are bent without substantial plastic deformation and attached thereto to form a skin. The skin contains a transparent portion allowing a driver to view the surrounding terrain, and portions of the skin are detachable from the frame to allow access to the inside of the vehicle body.

Abstract: A frame apparatus, and process for constructing same, for use in the construction of various vehicles. The apparatus comprises one or more frame members, each fabricated from a single longitudinal extrusion, and one or more cross-members. The frame members include a predetermined number of regions softened through a localized heating process. The softened regions are bent to varying radii in predetermined directions relative to the profile of a specific frame configuration and then allowed to harden back toward their pre-softened hardness.

Abstract: An automotive space frame joining system. The joining system includes a pair of extruded aluminum alloy lineal hollow rectangular members, the first lineal member having a top end, a bottom end and two opposing sides, each opposing side including a plurality of substantially similar longitudinal grooves running from the bottom end towards the to end of the first lineal member, the second lineal member having a top and a bottom longitudinal surface, the bottom end of the first lineal member abutting the top lineal surface of the second lineal member; and two pair of universal joining members, each joining member comprising a span and an interlocking member attached to the span, each pair fastened to opposing sides of the second lineal member and positioned such that each interlocking members of each joining member provides interlocking engagement within the opposing grooves of the first lineal member, thereby providing a space frame exhibiting great strength.

Abstract: An automobile chassis and a one-piece body integrated into a unitary structure, and a method for fabricating, assembling and integrating the chassis and body. The body includes interior panels, a cockpit, an engine enclosure module, and an underbody. The chassis/body structure, comprised of a single type of aluminum alloy and a single type of thermoplastic, is resistant to high-stress loads and is substantially recyclable into industrial-quality constituents. A first preferred embodiment includes a body rotomolded from a reinforced polycarbonate, polycarbonate/ABS blend, or polyimide thermoplastic, seven aluminum alloy bulkheads, and stacks of thin-wall aluminum honeycomb-cell panels embedded in an unreinforced foam of the thermoplastic. A second preferred embodiment includes a body rotomolded from a reinforced liquid crystal polymer thermoplastic, seven aluminum alloy bulkheads, and stacks of thin-wall aluminum honeycomb panels.

Abstract: A support structure for supporting a foamable material in a cavity of a hollow structural member so that the foamable material blocks the cavity of the hollow structural member when it is foamed by external heating. The support structure includes a support member including a main body which has an external dimension smaller than the dimension of a transverse cross section of the cavity, a foamable material receiving wall provided on the main body, and a restriction flange extending from at least one of the main body and the foamable material receiving wall. The support member is disposed in the cavity in such a manner that the restriction flange is substantially perpendicular to the longitudinal direction of the cavity. The foamable material has a substantially annular configuration and is profiled substantially to conform to the configuration of the transverse cross section of the cavity. The foamable material is arranged along the foamable material receiving wall of the support member.

Abstract: A joint structure includes an extrudate member and an elongated mating member, in which the extrudate member has a closed sectional structure portion and has its one end joined to the elongated mating member such that the longitudinal axis of the extrudate member intersects the longitudinal axis of the elongated mating member. The one end of the extrudate member includes an integral joint portion of a shape matched to the shape of an outer surface of the mating elongated member so as to encircle at least a portion of the elongated mating member. The joint portion is bonded to the outer surface of the mating member at its longitudinally intermediate portion by brazing, spot-welding or the like.

Abstract: Push-fit connecting joints comprising a node and at least one hollow section, where the node contains attachment parts and the attachment parts feature openings to accommodate connecting elements, and the hollow section features at least one hollow chamber and at least one opening for the connecting element. The openings in the hollow section are oversized with respect to the corresponding openings in the attachment part and the region of the opening on the outside of the hollow section is covered over by a cover sheet. The cover sheet features for each connecting element an opening having the dimensions of the opening in the attachment part, and an adhesive is provide between the cover sheet and the hollow section. The push-fit connecting joints may be employed in the construction of Space-frame parts.

Abstract: A structural beam, particularly for use as a door pillar or a bumper of a motor vehicle, includes a one-piece elongated extruded member formed of a light metal. The member has therethrough an elongated, laterally enclosed cavity defined by elongated side walls including at least two generally parallel side walls. A deformation pressure is applied to walls extending generally transverse to the two side walls, with the result that there occurs controlled folding of the two side walls with the formation therein of folds that extend parallel to the direction of elongation of the member. Thus, the cross-sectional area of the cavity through the member is reduced.

Abstract: A composite laminate beam for an automotive body construction has an outer structural portion an an inner tube portion separated by a thin layer of structural foam. The beam may take the form of a radiator support structure, a windshield pillar, a rocker assembly or a drive shaft or similar structures. A method of making the beam is also disclosed.

Abstract: The present invention provides an improved mobile body construction in the field of motor homes having relatively rigid side walls mounted to a floor above a chassis frame. A frame joint system is provided through use of metallic extruded joint members of a lightweight configuration, while maintaining a relatively rigid frame. These joint members are elongated and can be cut to the individual needs of the particular unit under construction, and comprise a hollow interior subdivided into strengthening polygonal cells. A floor interfacing beam is connected to the floor. The floor interfacing beam has a cross-section including two rectangular polygons and an approximately triangular polygon. The three polygons share a common surface which is parallel to the floor and are juxtaposed adjacent one another. A side wall interfacing beam is connected to the side wall, and has a cross-section including both a polygon having four sides and at least two approximately 90-degree angles and a vertical portion.

Abstract: A split joint construction for a space frame on an automotive vehicle includes at least one rocker member extending longitudinally, at least one structural member having extensions extending longitudinally in a first direction and in a second direction opposite to the first direction, each of the extensions having at least one channel to receive the rocker member, and a fastening mechanism for securing the structural member and rocker member together.

Abstract: A front wheel drive motor vehicle is made having a strong, light weight, and attractive arrow-like body made with steel square tubing. Easily removable and replaceable plastic panel inserts complete the body. Vehicle entry is step in style by rolling back the top. The top is also easily removable to make it a convertible type vehicle. The vehicles front wheels are driven through a bevel gear drive which provides a narrow wheel track and drives both front wheels simultaneously. Suspension and steering along with drive support is through a pair of special U-shaped springs. The U-shaped springs also provide a semi-independent front suspension. The vehicle has a wide rear wheel track for stability.

Abstract: The invention relates to an improved vehicle bodywork for a passenger car with a bearing structure of light-metal extruded sections connected together by cast light metal joining elements. The joining element is disposed on the A pillar assembly and is fitted between a downward sloping forward roof pillar and a vertically oriented forward door pillar and holds an extruded section front end fender brace which extends outwardly therefrom towards the front end of the vehicle. According to the invention, a portion of the outer profile of fender brace conforms to the cross-sectional shape of a surrounding fender panel connected thereto. In this way, the space beneath the fender panel is used to increase the cross section of the fender brace and hence increase rigidity. In a preferred embodiment, the fender brace is L-shaped in cross section having two approximately rectangular hollow-chambers including an outwardly disposed vertical hollow-chamber area and laterally inwardly extending horizontal hollow-chamber.

Abstract: A space frame apparatus, and process for constructing same, for use in the construction of various vehicles. The apparatus comprises one or more continuous outer frame members, each fabricated from a single longitudinal extrusion, and one or more cross-members. The extrusions include a predetermined number of slots for operable acceptance of the ends of the corresponding cross-members, as well as a predetermined number of regions softened through a localized heat induction process. The softened regions are bent to varying radii in predetermined directions relative to the profile of a specific vehicle configuration and then allowed to harden back toward their pre-softened hardness. The ends of the cross-members are also softened through a localized heat induction process, and then deformed so as to create a collar and flange portion operably positioned on opposite sides of each respective slot for securely maintaining the cross-members to the one or more continuous outer frame members.

Abstract: A loading bow device for open bed trucks which includes a front bow extending parallel to the width of the passenger's cabin. Both lower sides of the front bow are connected to lower bars. Each lower bar is also connected to the top of the corresponding side wall of the open truck and to a movable back bow extending parallel to the front bow. The back bow is connected at a number of places on the lower bar or is movable thereon. The device is advantageously provided with removable upper bars extending parallel to the lower bars, connecting the front bow to the movable back bow. The lower and upper bars may be provided with a number of connection points for the fixation of the movable back bow.

Abstract: In a light-metal vehicle body, a girder assembly joins a first longitudinal girder member located in a forecarriage region of the vehicle body to a second, laterally offset, and generally longitudinally oriented side sill member. The girder assembly includes a pair of open shell-shaped, light-metal castings which form a single, hollow section enclosure when brought together along their mutual open face regions. The concave interior surfaces of the shell-shaped casting are provided with a plurality of spaced integrally formed stiffening rib members. The stiffening ribs are oriented transverse to the curving longitudinal center axis of the girder assembly which curves in conformance with the Z-shape configuration. The stiffening ribs of each shell-shaped castings are arranged in coordinate pairs such that they formed a series of substantially continuous webs along an interior cross section of said girder assembly.

Abstract: The invention relates to a conical central pillar assembly for the bodywork of a passenger car, especially a bodywork having a space-frame bearing structure constructed from extruded light metal section bearers and cast light metal joining elements. According to the invention, the central pillar assembly includes a substantially plate-like base section wall having a multi-layer, multi-chamber extruded section disposed thereon. The section chambers in the outermost layers are selectively cut at various heights in step wise fashion in order to produce a desired conical cross section with a wide base portion and narrow top portion. Additional cuts are made in the outermost section chambers to form recesses for accommodating door locks, hinge assemblies and the like. An additional piece, preferably in the form of a light metal casting or a sheet metal stamping, is provided and forms an outer cover for at least a bottom portion of the central pillar.

Abstract: A vehicle body for motor vehicles, particularly passenger cars, has supports and receiving devices for vehicle components. In order to provide a receiving device which can be manufactured at low cost and is easy to mount and by which high forces can be absorbed and introduced into the vehicle body, the receiving device is formed by an extruded profile part connected with the vehicle body.

Abstract: A cast light metal joining element and method of assembly with adjoining extruded light metal hollow section bearer member of a space frame type vehicle body. The joining element or casting includes at least two spaced apart, location points disposed along a surface wall thereof. The location points permit the casting to be held in a corresponding fixture at a desired positionally correct spatial orientation to facilitate the fitting and connection of adjoining frame elements with greater ease, accuracy and smaller tolerances. In one embodiment, the location points include integrally formed conical studs and/or conical depressions. In another embodiment, the location points include through-holes, either straight cylindrical or conically tapered. The studs, depressions and/or holes also served a dual function in providing a positive locking connection to add on components which have corresponding matingly engagable connection surfaces.

Abstract: A center pillar in a motor vehicle constructed of two light metal extruded sections including a first extruded section having one vertical side cut at an acute angled .alpha. over its length and a second extruded section of a uniform cross section. The cut side of the first extruded section is mated to a vertical side edge of the second extruded section in such a way to produce a center pillar having a gradually tapering thickness from bottom to top. The first extruded section includes a bend region at a lower terminal end portion thereof which diverges from the first extruded section and which is cut at an acute angle for smooth transitional connection to a bottom disposed lengthwise connecting member. A plate member is provided for covering the gap created by the divergence of the first extruded section relative the second extruded section.

Abstract: A spring strut mounting assembly for fitting on a vehicle body which includes a spring strut having a bearing block mounted at the top end thereof on which elements of the running gear, such as a damper, a spring and link arms, can also be pre-mounted. Support members for attachment to the vehicle body adjacent the location for the suspension strut mounting assembly are provided and have converging free ends which define three boundary points of a free space region for mounting the upper bearing block of the spring strut. The upper bearing block is joined directly to these support members without the need for the conventional spring strut cup which is normally fixed to the vehicle body. In a preferred embodiment of the invention, the support members are aluminum extrusions and the converging free ends are each cut at an oblique angle to provide suitable large contact surfaces for mounting to the corresponding receiving flanges of the upper bearing block of the suspension strut.

Abstract: A space frame for an automotive vehicle includes at least one longitudinally extending structural member and at least one rocker including a structure forming channels on at least two sides, one of the channels receiving the structural member and an adhesive and/or sleeve for securing the structural member to the rocker.

Abstract: A rocker and various joint constructions are provided for a space frame on an automotive vehicle. Also, various methods are provided for constructing joints and joining subassemblies of a space frame together.

Abstract: A bearer joint for a vehicle bodywork, and in particular a longitudinal front bearer joint, and a process for placing an aluminum bearer on the bearer joint in the vehicle bodywork. The bearer joint comprises a cast aluminum connector for joining together a first forward bearer and a second adjacent bearer. The connector includes a tubular aluminum recess for receiving the rearward end of the first aluminum bearer which is fixed thereto by a transverse weld seam at the front receiving edge of the recess. To replace a damaged front bearer, a ring cut is made to the outer wall of the aluminum recess at a distance from the forward receiving edge corresponding to the zone of thermal influence of the heat affected zone adjacent the weld. A damaged front bearer is then withdrawn from the recess and replaced by a new front bearer which is also welded to the new forward cut edge of the aluminum recess. In this way the front bearer is replaced without compromising the original strength of the bearer joint.

Abstract: A torque box for a space frame on an automotive vehicle having at least a pair of spaced vertically extending structural members includes an inner panel, and an outer panel spaced from the inner panel and substantially parallel thereto. The torque box includes a plurality of interior panels extending between and interconnecting the inner and outer panels. The inner and outer panels and interior panels cooperate to form a spaced ends which are secured to the structural members.

Abstract: The coach body construction comprises an upper structure having extruded profiles, which are connected detachably to one another by corner connectors and are made of an aluminum alloy, and a lower structure. The lower structure is composed of longitudinal and transverse supports which are made of an extruded aluminum alloy and are detachably connected to one another and to the upper structure by corner connectors. In interaction with the upper structure, it is of inherently sturdy construction. The corner connectors are, in particular, screw-on corner connectors.

Abstract: An improved mounting arrangement for an automotive vehicle cross car beam provides a connector arranged on each end of the beam configured to wedgingly engage reciever slides formed in the front pillars of the vehicle.

Abstract: A space frame for an automotive vehicle includes a plurality of structural members and joint constructions for joining the structural members together such that the outer surfaces of the structural members are substantially flush with each other.

Abstract: A motor vehicle body assembled from a plurality of metal frame profiles held together by node connector elements. Each metal frame profile includes an extruded metal portion and a pre-shaped sheet metal portion attached thereto to form a portion of the outer skin of the completed motor vehicle body. Each pre-shaped sheet metal portion is secured to the extruded metal portion so that it overlaps a part of the outer contour of the extruded metal portion to define an enclosed hollow space. This provides a box-type construction which increases strength and rigidity of the combined frame profile.

Abstract: A hollow beam 2 includes provisions (12, 13, 14 and 15) to allow mounting a spacer sleeve or support body 6 in its intended location for insertion of a mounting bolt 5 from outside the beam 2. The sleeve (6) at least partially encompasses the mounting bolt 5 and is inserted through an access opening (11) into the hollow beam 2 and is subsequently positioned in registration with attachment holes and which recive the mounting bolt 5.

Abstract: An improved mobile housing structure is provided having a pair of side walls with a plurality of vertical support posts extending upward from a chassis. The vertical support posts are connected to an elongated side wall joint member of a honeycomb configuration. A modular roof section having a plurality of roof support members extending between a pair of roof joint members is formed of a sandwich construction with styrofoam block members adhesively connected to overlapping panels. The roof joint members can be riveted to the side joint members to provide an extremely lightweight and rigid structure that can resist transportational torque stresses.

Abstract: A space frame for an automotive vehicle includes a plurality of hoop-shaped structural members and a structure disposed on adjacent portions of the structural members for allowing nesting engagement therebetween to form a substantially flush outer surface between the structural members. The structure includes at least one shoulder portion and at least one extension portion on one of the structural members.

Abstract: A body skeleton structure for a vehicle includes an outer panel arranged on the outside of a body, and an inner panel arranged on the inside of the body. The inner panel cooperates with the outer panel to define a closed cross-sectional space. A bracket is arranged between the outer panel and the inner panel. A thermally foaming rubber sheet is provided on a surface of the bracket. The thermally foaming rubber sheet is so heated and foamed as to be into close contact with the outer panel and/or the inner panel.

Abstract: A front body structure for vehicles comprises a side sill formed by a first frame and a second frame each having closed cross sections, wherein the first frame is curved upwardly and is further curved inwardly in a transverse direction of a vehicle body so as to form a cowl front portion and the second frame is curved inwardly in the transverse direction of the vehicle body so as to form a dash cross portion, and a front side frame which bifurcates into two bifurcated portions in a vicinity of a front side portion of the vehicle body. The first and second frames are respectively joined to end portions of the bifurcated portions, substantially even therewith. An end portion of a lower bifurcated portion of the front side frame is joined without offset to the dash cross portion. An end portion of an upper bifurcated portion of the front side frame is joined without offset to the cowl front portion. Consequently, load inputted to the front frame can be received by the side sill via the first and second frames.

Abstract: A motor vehicle body structure has a pair of side frames each comprising a core layer having opposite surfaces and a pair of outer skin layers covering the opposite surfaces, a motor vehicle component, and joints disposed between the side frames and the motor vehicle component, for joining the motor vehicle component to the side frames through surface-to-surface contact therebetween.

Abstract: An emergency rescue vehicle which includes a patient compartment which is accessible for patient loading through doors located along both sides and rear of the vehicle and wherein the primary patient support stretcher is pivotally carried centrally of the compartment and is extendable outwardly through any one of the access doors. The patient compartment is separated between tandem front wheel assemblies and a rear wheel assembly to obtain a continuously level and low loading height and the primary patient support is positioned generally at the center of mass of the vehicle.

Abstract: A general delivery load carrying vehicle comprising a unitized load and stress bearing monocoque body and a front wheel drive engine unit. The body comprises a base floor, side walls and a top wall or roof structurally interconnected to support the vertical and torsional forces on the vehicle. The base floor has a length sufficient to provide a cab area and a load carrying area. The base floor is such as to provide a floor in the cab area that is at the same height throughout and at a level such that persons entering the vehicle may step into the vehicle directly in a single step without the need for additional structural steps or running boards. The side walls have openings adjacent the cab area for entrance and exit and one end wall defines structural pillars for receiving the windshield.

Abstract: A passenger car, particularly a sports car, has a vehicle body with an aerodynamically advantageous construction which comprises a windshield, a top, a rear window and door window panes above a belt line. For creating a passenger car with a changeable top configuration and having a vehicle body and a top of a simple construction that can be manufactured at reasonable cost and have a low weight, it is provided that a continuous supporting frame extends along the upper edge of the windshield, the door window panes and rear side windows situated behind them, the top and the rear window being detachably fastened to the frame.

Abstract: A method of producing a vehicle body structure having a pipe-shaped structural part reinforced with a hard and high density foamed polyurethane resin. The method is carried out as follows: First, a plurality of pressed panels are prepared, the pressed panels being to be joined to form the pipe-shaped structural part. A band-shaped foamable rubber which has not yet foamed is attached onto the inner surface of each of a plurality of panels at a predetermined position. The panels are joined to form the pipe-shaped structural part. The foamable rubber is foamed under heating in a painting step to form a foamed rubber at the predetermined position. Then, a foamed member of a soft foamed polyurethane resin is inserted into an opening formed within the pipe-shaped structural part and defined by the foamed rubber in order to constitute a dam section for blocking the pipe-shaped structural part at the predetermined position.

Abstract: The invention relates to the construction of motor vehicle bodies. The vehicle bodies are constructed from a lower section formed of pressed metal panels connected together, and an upper section formed of frame elements. The lower section functions as a primary strength imparting component of the vehicle body, and the upper section functions as a primary style imparting component of the body. The configuration of the upper section can be varied by varying the arrangement of configuration of the frame elements so that the style of the vehicle body can be varied without necessitating a change to the lower section. The lower section will thus remain substantially unchanged for a range of vehicle styles or models.

Abstract: A small, three wheeled utility vehicle has a front steering wheel and two rear drive wheels driven by an automotive engine and transaxle unit. The vehicle has a frame composed of tubular steel parts welded together to provide a complete cage around the passenger compartment and an engine and cargo area behind the passenger compartment. The body of the vehicle is composed of body panels mounted within the tubular frame.

Abstract: A member, particularly a side member of a vehicle body structure, is formed by an extruded section manufactured or light metal which, viewed in the vertical direction, has at least one hollow-section portion. In order to achieve a high energy absorption in the case of an impact shock and for the space-saving connection of an impact-absorbing damper of a bumper arrangement, the member comprises a central tube portion and two outer hollow-section provides which are connected to the tube portion by diagonally extending webs.

Abstract: A mounting structure for a vehicle deceleration sensor, comprising a deceleration sensor mounted on a part of a vehicle body where a longitudinal end of a front side member extending along a fore-and-aft direction of the vehicle body on one side thereof and a bulkhead separating a passenger compartment from a front part of the vehicle body are joined together with a part of the deceleration sensor protruding into the hollow interior of the front side member. Thus, a deceleration resulting from a vehicle crash is quickly transmitted to the deceleration sensor through the front side member, and the deceleration sensor is protected from adverse environmental effects as it may be located in the interior of the front side member.

Abstract: A composite windshield framing structure is provided for a convertible automobile. The framing structure includes a tubular metallic inner frame which is encapsulated by foam material. A layer of reinforcing fabric impregnated with plastic overlies the foam material and also defines an instrument panel ledge with downwardly extending cowling.

Abstract: In the typical embodiment described in the specification, a rigid frame structure for an end region of a motor vehicle is assembled exclusively from triangles of elements in an octahedral arrangement so as to provide a favorable force-to-travel characteristic in the event of a collision. In the octahedral arrangement, an end triangle of elements forming the end of the vehicle points upward with an apex, and a triangle of elements that is substantially parallel to the end triangle and serves the purpose of mounting to an adjacent vehicle region and has a downwardly pointing apex.

Abstract: Apparatus for connecting two tubes in a T-shape which permits the tube which is extended perpendicular from the middle of the other tube to be adjusted to a certain degree about the circumference of the other tube before the tubes are secured to one another.

Abstract: A barrier to the passage of sound, vibration, and moisture through a hollow channel in a motor vehicle body and a method for producing same are provided. The barrier is comprised of a resilient body such as flexible foam and a heat-deformable member such as a tube which defines a passageway between the ends of the resilient body when the resilient body and the member are mounted in the hollow channel. The barrier may be coated with hot melt adhesive. The barrier is mounted in the hollow channel and the motor vehicle body is dipped in a paint bath and drained. Paint flows in and out through the passageway in the barrier, thus coating the interior of the hollow channel. When the motor vehicle body is passed through the bake oven, the heat-deformable member collapses, the barrier is closed, and the hot melt adhesive bonds the barrier to the channel.

Abstract: A vehicle space frame comprising load bearing longitudinal structural members (2) formed from an integral extruded multicavity shape being split, reshaped and aligned to secondary complementary shaped members (8) is provided. A new method of joining the structural members is based on longitudinal internesting of complementary shaped outer surfaces of the members forming the supportive structure of the space frame.

Abstract: A child's ridable vehicle is disclosed which includes generally first and second body portions with proximal ends overlapped and secured at alignment apertures to a frame of the vehicle. The second body portion overlaps the first body portion at still portions of each which are inverted U-shaped sections overlapped on the frame. The second body portion has a unitary post bushing passing through the alignment aperture in the first body portion and into an aperture in the frame to be secured by a threaded fastener and this locates both body portions relative to each other and to the frame. The two body portions may be assembled by placing them at a wide angle V and nesting them together then straightening out the two parts to be in common plane and mating them with the frame with a threaded fastener inserted through the frame and securing the two overlapped body portions to the frame.