Abstract:
A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.
Abstract:
An assembly of supporting members includes a first member (14) overlapping a second member (16) and positioned within a recess (176) of the second member. The second member has a flange (168) on which the first member rests. In front of a leading edge (148) of said flange, a protrusion (150) extending away from the first member permits the flange and the connection between the first and second members to be protected. The first and second members may be hydroformed with the protrusion being an integral element of the first member.
Abstract:
A welding material in positioned in electrically conductive relation between exterior surface portions of first and second weldable members (18, 22), such as hydroformed tubes, at a location where the first and second weldable members are to be joined. A welding device comprises first and second electrodes or conductive ends (46, 48) that extend along substantially the entire extent of first sides of the first and second weldable members, respectively. The first and second conductive ends include first and second concave recesses (158), which nest with the first and second weldable members (18, 22), respectively. Axial pressure and electrical current are applied across the first and second weldable members by the nesting first and second conductive ends. The applied current melts the welding material and thereby welds the exterior surface portions to one another. The welding device can be mounted on a robotic mechanism, which can move the welding device between first and second welding positions.
Abstract:
A vehicle door system includes doors with a door module attached to a hinge module, which is attached to the vehicle body. The door module includes a latch mechanism configured to engage a striker pin of the vehicle body, with a pawl that pivots to accommodate a misalignment with the striker pin during a door closing operation, with the latch mechanism shifting following engagement with the striker pin. A door check mechanism includes a permanent magnet and a steel plate. Activation of the permanent magnet shifts the steel plate from a closed position to an open position permitting the hinge module to move from a locked position. An interface between doors includes a primary and secondary seal each having a constant cross section, with filler pieces disposed between the door and the secondary seal along a portion of the interface.
Abstract:
A system for modifying the range capability of an electric vehicle includes a vehicle body having a front axle and a rear module secured to the vehicle body. The rear module includes a rear axle and the rear module is detachable from the vehicle body and replaceable with another rear module. The rear modules may include different range extension capabilities. The rear modules may include a battery or a combustion engine that may supplement the standard battery and electric motor of the vehicle. A pair of laterally translatable pins of the rear module may be moveable into and out of engagement with the vehicle body. The rear module may also include vertically extending posts that engage with the vehicle body. The vehicle body may be raised to disengage the posts from the vehicle body.
Abstract:
A system for modifying the range capability of an electric vehicle includes a vehicle body having a front axle and a rear module secured to the vehicle body. The rear module includes a rear axle and the rear module is detachable from the vehicle body and replaceable with another rear module. The rear modules may include different range extension capabilities. The rear modules may include a battery or a combustion engine that may supplement the standard battery and electric motor of the vehicle. A pair of laterally translatable pins of the rear module may be moveable into and out of engagement with the vehicle body. The rear module may also include vertically extending posts that engage with the vehicle body. The vehicle body may be raised to disengage the posts from the vehicle body.
Abstract:
A solar panel assembly is provided including an array of reflective panels and a chassis assembly for supporting the array of reflective panels. The chassis assembly includes a plurality of support arms extending radially outwardly from a central hub. A plurality of brackets interconnect the support arms with the reflective panels. A plurality of the brackets are L-shaped brackets attached to an adjacent reflective panel at one point and a plurality of the brackets are J-shaped brackets attached to an adjacent reflective panel at two points. Each bracket includes an elongated slot, through which it is attached to one of the supporting arms. The elongated slot allows the same type of bracket to be used at various points along the support arm and to attach the same type of support arm to reflective panels having different curvatures.
Abstract:
A cross member for a motor vehicle includes an elongated, non-cast center structure and first and second castings. The center structure is formed as a one-piece, unitary structure and has a first end, a mid portion, and a second end. The first casting is rigidly connected to the first end of the center structure and the second casting is rigidly connected to the second end of the center structure. Each of the castings is configured and arranged to be attached to a respective motor vehicle element.
Abstract:
A door seal interface structure (12) for a motor vehicle space frame (10) includes a longitudinally extending hydroformed tubular rail portion (14), a hydroformed tubular pillar portion (26) connected at a joint to the rail portion and a transition structure. The rail portion and the pillar portion provide respective surface portions constructed and arranged to sealingly engage a door seal to seal a peripheral portion of a closed vehicle door. The pillar and rail surface portions are angularly related to one another in the vicinity of the joint. The transition structure is mounted on the rail portion and the pillar portion in the vicinity of the joint and provides a transition surface (12a, 12b) that provides a transition between the pillar and rail surfaces of the pillar and rail portions, the transition surface portion being constructed and arranged to sealingly engage a portion of the door seal to seal the closed vehicle door and thereby provide a door seal-engageable surface in the vicinity of the joint.
Abstract:
A space frame for a motor vehicle having a pair of laterally spaced, longtitudinally extending side rail structures, a pair of forward-most upright structures each being connected to a respective side rail structure, thereby forming a pair of A pillars, a pair of roof rail structures, a forward end of each roof rail structure being connected to an upper end of an associated A pillar, and a rearward ring assembly connected at upper portions thereof with the roof rail structures and at bottom portions thereof with the side rail structures. The rearward ring assembly having (a) a tubular hydroformed inverted U-shaped upper member having a cross portion, (b) and a pair of leg portions extending downwardly from opposite ends of the cross portion, (b) a pair of tubular hydroformed side members, and (c) a cross structure rigidly connected in ring-forming relation between the second ends of the side members.