Ford Global Technolgoies, LLC

Ford Motor Company Limited

John T Reed

Henry W Hausler

Paul Elia

Lawrence Anderson Queener

James Wayne Lowe

Jason Scott Balzer

Hikmat F Mahmood

Jaspinder S Sahi

Lou Ratsos

Frank J Day

Tyler Jon Blake

Stephen Lewis Bruford

Peter Ellis Hackett

Gregory S Frederick

Dean A Gericke

Rong Yao

Ramakrishna P Koganti

Gavin Smith

Sergio Angotti

Matt Edward Maser

Alexandre Costa Henriques

Bryan Mikula

Joe Weishaar

A compensator assembly for a vehicle frame includes a base member having a clip engaging a first frame component spaced from a second frame component. An extension member is threadably coupled with the base member. A fastener extends coaxially through the base and the extension members to engage the first and second frame components. Rotation of the fastener unthreads the extension member until it contacts the second frame component.

Compensator assembly for a vehicle frame

A tolerance compensator for a vehicle frame includes a base member having an upper portion in keyed engagement with a roof structure. The tolerance compensator also has an extension member that is threadably coupled with a lower portion of the base member. A fastener extends up from a body-side structure to threadably engage and move the extension member down into contact with the body-side structure before threadably engaging the base member.

Tolerance compensator for a vehicle frame

A hydroforming process forms a hydroformed automotive component as a multiple cell member having an integral internal rib separating the cells and reinforcing the hydroformed component to increase the strength of a hydroformed component with a given size and shape. The tubular blank can be manufactured through a roll-forming process or by welding two structural tubular members, to form a tubular blank that has multiple cells with an internal rib separating the cells. The hydroforming process injects fluid under pressure into each of the cells to expand the tubular blank into the shape defined by the die holding the blank. The internal web separating the cells of the blank becomes an integral internal reinforcement spanning the component to enhance the strength, rigidity and stiffness of the component. Providing differential pressure on the multiple cells can stretch and twist the internal rib for positioning internally as desired.

Double hydroformed tube with integral reinforcement

A roll-forming process for the manufacture of a structural member can be used in the manufacture of an automotive vehicle. The roll-forming process creates a component that has multiple cells with an integral internal web separating the cells, enhancing the strength, rigidity and stiffness of the component for any given size and shape. The roll-forming process starts with a piece of sheet metal and rolls the sheet metal into a desired shape and then rolls the tube back over on itself to create a second cell with the internal reinforcing web positioned between two structural cells of the beam. The rolled form is then welded into the formed shape to create the structural beam. The two cells of the beam can be the same general size or be formed as completely disparate sizes, depending on the design requirements of the structural member.

Method of roll-forming an automotive support member

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 body side rail construction for an automotive vehicle is formed in a dual cell configuration. A reversed C-shaped channel is welded to the closed section of the conventional roof side rail member to enable the body side rail member to be a smaller section that is less susceptible to buckling as the body side rail member transfers load to the front and rear corner pillars. The C-shaped cross-sectional configuration presents advantages for manufacturing as it can be shaped to provide the attaching brackets and horns for mounting the front header, roof bow, and rear header members to the body side rail without the addition of individual end items to serve this function. From a shipping density standpoint, this design gives maximum structure while maintaining good rack density that enables relatively straight parts to be nested together while still providing the increased section strength required for enhanced roof performance.

Dual cell body side rail for automotive vehicles

A dual cell rear corner pillar for the operator's compartment of a pick-up truck is formed with longitudinally oriented front and rear tubular members. The dual cell tubular construction increases section strength for the rear corner pillar while maintaining packaging constraints for the rear pillar design. The front tubular member is nested against the rear tubular member to provide support therefor longitudinally and vertically. The forward tubular member is welded to the door opening panel seal flange, while the rearward tubular member is welded to the window flange and the back panel flange. The forward and rearward tubular members are also welded to one another to form a strong pillar structure. The dual cell configuration resists buckling and shares loading. The rear tubular member wraps around the front tubular member and transitions into the roof rail area, shortening the unsupported moment arm of the rear tubular member.

Dual cell rear corner pillar for automobiles

An A-pillar structure on an automotive vehicle is manufactured from a formed tubular member that replaces the conventional inner and inner reinforcement members. The door opening panel is formed with conventional flanges that are welded or adhered to the tubular member to provide a conventional uniform surface against which the windshield and front door seals can be supported. The door opening panel flanges can be welded by one-sided welding techniques, such as laser stitch welding, to the tubular member. As an option, the movement of the front door seal from the ab flange to the front door can provide an opportunity to form the tubular member with a still larger cross-section for enhanced strength. The distance dimension spanning the opposing flanges to define the standard arc for maintaining binocular vision is retained while increasing the strength of the A-pillar due to the enlarged cross-sectional configuration provided by the tubular member.

A-pillar structure for an automotive vehicle

A storage compartment is formed on the lateral side of a pick-up truck to have a door that will open to a generally horizontal position to permit use thereof as a step to facilitate access to the interior of the cargo bed. The storage compartment door is pivotally supported by a pivot mechanism that is supported from the underside of the pick up box to provide sufficient support thereof to withstand the weight of a person utilizing the door as a step. The door is also provided with supplemental support members interconnecting the door and the underside of the pick up box. When closed, the door conceals the pivot mechanism to provide a smooth, clean line on the exterior surface of the truck. The opened door allows access to a storage compartment that preferably extends beneath a portion of the cargo bed to allow storage of small items in a contained compartment.

Storage compartment and step for pick-up trucks

An automotive vehicle body includes a floor structure, a roof structure and a door opening panel welded to the floor and roof structure. The door opening panel is formed from a tailor welded metal blank furnishing a first thickness of metal for a lower portion of the door opening panel and a second thickness of material for an upper portion of the door opening panel. The lower and upper portions of the door opening panel are joined at an approximately horizontal weld line which is concealed by a passenger door, and in one embodiment, a pickup box.

Automotive vehicle body having tailor welded blanks

A vehicle roof structure including a front header, a pillar support member, a side roof rail, and a roof rail outer front member. The front header has a substantially box-shaped cross-section. The pillar support member has an elongated member extending between a windshield opening and a door opening, a short first member at one end of the elongated member extending along the windshield opening, and a short second member at the end extending along the door opening. The first member includes a first edge adjoining an end of the front header. The side roof rail has a substantially box-shaped cross-section and adjoins a second edge of the pillar support second member. The roof rail outer front member is affixed to the pillar support member. The roof rail outer front member adjoins the end of the front header in a region of the first edge, adjoins the side roof rail in a region of the second edge, and extends along at least a portion of the elongated member of the pillar support member. The roof rail outer front member and the pillar support member form a substantially box-shaped cross-section extending between the first, second and elongated members such that a continuous substantially box-shaped cross-section exists throughout the joint defined by the vehicle roof structure.

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Northville, MI, United States of America

John T Reed