Ford Global Technolgoies, LLC

Larry J Dupuis

Dragan B Stojkovic

James Wayne Lowe

Michael Musa Azzouz

Raj Sohmshetty

Aaron Peter Klop

Stephen Lewis Bruford

Musa Azzouz

Paul Lee Luskin

Madhu R Deme

Matt Happy

Michael John Lang

An A-pillar joint configuration where the front end frame rail members are welded to the A-pillar eliminates the seals at the interface between the front end frame rail members and the A-pillars. The front flange of the A-pillar is also eliminated in the hydroformed configuration while the hydroformed frame rail members are formed with rearward ends that mate with the shape of A-pillar to positioned flattened ends against the exterior vertical side of the A-pillars for welding thereto. The resulting joint configuration eliminates the openings in the A-pillar for the passage of the front end frame rail members requiring seals to insulate the passenger compartment from engine and road noises.

A-pillar joint for automotive vehicles

An automotive body structure includes a tubular load bearing structure and a hardware mount having a base plate with an annular axially extending spin welding initiator. The hardware mount is spin welded to the load bearing structure to provide a reinforced location for the mounting of automotive hardware, such as door hinges, with threaded fasteners.

Automotive body structure with spin welded hardware mounts

An improved method of manufacturing an assembly comprising at least two components. Assembly components are attached together to form a combined assembly. The combined assembly is engaged by a single framing fixture that establishes the spatial relationships between each of the assembly components. After the spatial relationships are final, the assembly is fixed having securing points that are accessible when engaged by the single framing fixture. The method significantly reduces the load-weld-load sequences used in conventional body-in-white framing processes for motor vehicles.

Single set geometry method for assembly of a vehicle

An integral assembly for an automotive vehicle includes a battery tray, a coolant reservoir and a vacuum reservoir. The battery tray and portions of the coolant reservoir and vacuum reservoir are formed as a single molded part having shared partition walls, so as to provide superior strength, economy, and packaging efficiency.

Integral engine utility assembly for an automotive vehicle having a battery tray, coolant reservoir and vacuum reservoir

A process for spot-welding hydroformed members allows at least one hydroformed member to be positioned with an end butted against a lateral side of the second hydroformed member. A structural shell member sandwiches the joint around the two hydroformed members to provide a surface to which each of the hydroformed members can be spot-welded. The U-shaped structural support receives the lateral side of one hydroformed member in the bight portion thereof and has arms that are positioned against the perpendicularly positioned second hydroformed member. Each of the hydroformed members are formed with access openings therein to allow spot-welding electrodes to be positioned against an appropriate wall of the hydroformed member and the adjacent portion of the U-shaped structural shell member. The joint is rigidly formed by spot-welding each of the hydroformed members to the structural support. The process is particularly adapted for utilization in the manufacture of automotive frames.

Spot-welded joint for hydroformed members

In integral utility assembly for an automotive vehicle includes a coolant reservoir and an air cleaner. A mounting bracket for attaching the assembly to an engine compartment structure is co-molded with an air cleaner base and a lower portion of a coolant reservoir, so as to form an assembly having strength required for mounting with a single mounting plate.

Integral coolant reservoir and air cleaner for automotive vehicle

A vehicle support structure for supporting engine compartment accessories such as a battery. The support structure includes a first tubular frame member having a transversely extending portion and a longitudinally extending portion that partially encompass an accessory tray. A second tubular frame member disposed at least in part adjacent to the first tubular frame member and having a transversely extending base support portion that extends below the accessory tray. The accessory tray is secured to the first tubular frame member and overlies the base support portion of the second tubular frame member. The structure reduces the weight and number of parts required to support accessories.

Battery support structure

A front end assembly for a vehicle includes a U-shaped tubular structure, a body portion having a pair of laterally-spaced, longitudinally extending cowl sides, and, a pair of laterally-spaced A-pillar structures. The U-shaped tubular structure is secured to each A-pillar and each cowl side at longitudinally-spaced apart locations. The laterally-spaced connection points provide improved rigidity and reduce distortion.

Tubular front end structure for automobiles and method for making the same

One embodiment of the present invention is an improved front-end to body-side joint () for an automotive vehicle. This joint () includes an integral front end structure () having a fender attachment portion () and one or more hinge-reinforcement portions (). The fender attachment portion () is coupled to a fender (). Moreover, the hinge-reinforcement portions () are attached to a pillar member () of a vehicle body () for supporting a door (). The integral front end structure () is a master-locating component for positioning the fender () and the door () in a predetermined configuration within the joint ().

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Grosse Ile, MI, United States of America

Larry J Dupuis