Ford Global Technolgoies, LLC

Ford Motor Company Limited

Vari-form, Inc.

Jason Scott Balzer

Paul Kenneth Dellock

Lawrence Anderson Queener

Michael Henry Maj

S George Luckey, Jr

Amanda Kay Freis

Henry W Hausler

Vladimir Vladimirovich Bogachuk

Andrey M Ilinich

Aindrea McKelvey Campbell

David John Hill

James Wayne Lowe

John T Reed

Joy Hines Forsmark

Alexander Mamutov

Kim Lazarz

William P Edmunds

Michael Musa Azzouz

John Patrick Joyce

Raj Sohmshetty

Ari Garo Caliskan

Zhenyan Gao

Edward Andrew Pleet

Hikmat F Mahmood

Constantin Chiriac

Patrick James Blanchard

Rohit Telukunta

Dean A Gericke

Ryan John Craig

Joshua Jacob Clement

Todd Mueller

Mikhail Minevich

Kumar Mahadevan

Ramakrishna P Koganti

Vlad Bogachuk

Yuan Zhou

Dean Gericke

A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Mechanical joining top sheet isolation

A method of quenching a press hardenable steel is provided. The method includes an initial step of die quenching a part stamped within a stamping die followed by a partial quenching after the initial step of die quenching. In various methods, the press hardenable steel is a 36MnB5 grade steel and/or the initial step of die quenching is performed at a temperature of approximately 200&#xb0; C.&#xb1;10&#xb0; C. in a die configured for 36MnB5 grade steel. At least one method further includes opening the die followed by the partial quenching, the partial quenching comprising spraying a cooling liquid onto the part to reduce a temperature of the part below approximately 130&#xb0; C.&#xb1;10&#xb0; C., with the option of spraying to reduce the temperature of the part below approximately 100&#xb0; C.&#xb1;10&#xb0; C.

Hybrid quench process for hot stamping of steel parts

A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Method of manufacturing a lightweight laminate

A system for attaching material stack-up layers of at least two layers together using mechanical fasteners is disclosed. The material stack-up comprises at least an upper layer and a lower layer. The lower layer has a relatively constant thickness equal to or greater than 4.0 mm or may have alternating thick and thin areas in which the thickness of the thick area is equal to or greater than 4.0 mm. A mechanical fastener attaches the upper layer and the lower layer and is inserted at least partially into the lower layer. The fastener is inserted into the thick area of the embodiment having alternating thick and thin areas. The lower layer may be any of a variety of materials, including magnesium or any other brittle material. The lower layer may also be a casting, such as a magnesium casting. The mechanical fastener may be any of fasteners, screws or bolts.

Increased bottom sheet thickness on cast alloys for mechanical joining of certain materials

This disclosure details overmolded vehicle sheet metal structures that included integrated attachments for achieving part integration. An exemplary sheet metal structure includes a sheet metal panel, a reinforcing structure molded on the sheet metal panel, and an integrally molded attachment structure formed within the reinforcing structure. In some embodiments, the integrally molded attachment structure may include a nut, a bracket, or both. An additional vehicle component may be attached to the sheet metal panel via the integrally molded attachment structure. The sheet metal structure may be formed in a single shot injection molding process.

Overmolded vehicle sheet metal structures with integrated attachments

A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discrete layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

A vehicle body assembly includes an outer component defining a cavity. The outer component has a pair of first flanges. An inner component has a pair of second flanges each joined to one of the first flanges. A reinforcement formed of carbon fiber is disposed in the cavity between the components. The reinforcement includes a faceplate joined to the outer component with a rivet and third flanges each joined to the inner component with a rivet.

Vehicle body component

A shock tower assembly includes a cast shock tower body composed of magnesium or magnesium alloy and at least one steel bridging bracket. An insulating adhesive layer is formed between the tower body and the bracket. A mechanical fastener is used for fastening the tower body to the bracket. One or more structural ribbings are formed on the tower body. The mechanical fastener may be selected from any of several mechanical fasteners, including self-piercing rivets. Alternatively, a screw boss may be formed for receiving a screw. The rivet may be inserted from the bracket into the shock tower body or from the shock tower body into the bracket in which case an insulating layer is positioned between the head of the self-piercing rivet and the cast shock tower body. A sealant is preferably formed along the intersection of the cast shock tower body and the steel bridging bracket.

Thin-walled magnesium diecast shock tower for use in a vehicle

A vehicle frame includes an outside rail section having an upper flange, a lower flange, and an inward facing cavity between the upper and lower flanges. An inside rail section is coupled along the upper and lower flanges of the outside rail section and has an outward facing cavity that aligns with the inward facing cavity to enclose an interior volume. A pair of hydroform tubes extending vertically through apertures at spaced longitudinal locations in the upper flange and engage a bottom surface of the inward cavity to define a pillar for supporting a vehicle roof.

Vehicle frame rail and pillar connection

A vehicle roof panel for channeling fluid includes a raised formation at a centerline of the vehicle, and a plurality of primary troughs disposed laterally on either side of the raised formation. Each of the primary troughs defines a base surface that is recessed below a global runoff curvature of the roof. The roof panel also includes a secondary trough positioned laterally outboard of the primary troughs that defines a base surface that is substantially aligned with the global runoff curvature.

Vehicle roof for water management

A body side construction for an automotive vehicle is formed from multiple tubular members arranged to maximize the strength of the body side members while minimizing the amount of material utilized in the manufacture of the body side members and, thus reducing the cost of manufacture of the automobile. The body side members are formed from tubular members preferably manufactured through a hydroforming process. The tubular members extend from the front pillar to the rear pillar and can vary in number and in size as appropriate for the load being carried by the body side members. The tubular members can also be used to transition from the body side portion of the automobile to the roof structure to provide an integrated frame assembly. The formation of the body side members from multiple tubular members also creates an internal reinforcement web to further enhance the strength of the section.

Multiple tube body side construction for automobiles

A moon roof frame module is sized to span between the laterally spaced roof side rails of an automotive roof frame structure and is welded to the opposing roof side rails to be integrated into the roof frame structure. As a result, the moon roof assembly serves as a load path member to reinforce the automotive roof structure. The integrated moon roof frame module will receive roll over forces and increase the strength of the roof structure of an automotive vehicle. The moon roof frame module includes a U-shaped roof panel that is welded to the opposing roof side rails and provides a reinforcing cross member located forwardly of the moon roof opening. A second cross member positioned rearwardly of the moon roof opening increases rigidity of the reinforcing moon roof frame module.

Moon roof frame module for reinforcement of automotive roof

A structural joint configuration is used in an automotive body structure in which a transverse roof cross member has a convoluted formed shape that must be connected to the longitudinally extending tubular roof side rail. A two-piece clam shell bracket forms the joint apparatus. A lower piece formed in a shape to mate to and receive the transverse roof cross member is welded to the underside of the tubular roof side rail while projecting a formed receiver to engage the transverse roof cross member. An upper piece clamps over top of the transverse roof cross member and is welded to the top portion of the tubular roof side rail. The joint apparatus can be secured to the transverse roof cross member and to the roof side rail by either welding or by adhesives to provide a reinforcement at the joint between the two structural members.

Clam shell bracket connecting automotive structural members

A multi-functional radiator support assembly is provided for a motor vehicle. The multi-functional radiator support assembly includes a radiator support for operative attachment to forward end of the motor vehicle. The radiator support is made of magnesium or a magnesium alloy material.

Growing community of inventors

Canton, MI, United States of America

Jason Scott Balzer