An energy absorbing and distributing side impact system for use with a vehicle is provided, the system utilizing a battery pack enclosure that includes a plurality of cross-members that transverse the battery pack enclosure and absorb and distribute at least a portion of the load received when either the first or second side of the vehicle receives a side impact. The battery pack enclosure is positioned between the front and rear vehicle suspension assemblies and mounted between, and mechanically coupled to, vehicle structural members (e.g., rocker panels) located on either side of the vehicle. In addition to providing rigidity, strength and impact resistance, the battery pack cross-members segregate the batteries contained within the battery pack enclosure into battery groups.

System for absorbing and distributing side impact energy utilizing an integrated battery pack

A compact vehicle production line is disclosed. The production line comprises a floor process of assembling floor constituent parts. Each is an aluminum alloy extrusion die cast product, which has been made, in an extrusion die casting process, by forcing molten aluminum alloy through a mold cavity in a predetermined direction. The assembled floor constituent parts are welded to make a floor structure. In an interior parts mount process, interior parts are to the floor structure to make a floor unit. In a body main process, each of two body side structures are trimmed to make a body side unit. A roof structure is trimmed to make a roof unit. The floor unit, the body side units, and the roof unit are assembled. The assembly is welded to make a body unit. In a running parts mount process, an under running unit is mounted to the body unit. In an exterior parts attachment process, color body panels are attached to the body unit.

Production of vehicles

Precision-folded, high strength, fatigue-resistant structures and a sheet therefore are disclosed. To form the structures, methods for precision bending of a sheet of material along a bend line and a sheet of material formed with bending strap-defining structures, such as slits or grooves, are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves through the sheet of material in axially spaced relation to produce precise bending of the sheet when bent along the bend line. The bending straps have a configuration and orientation which increases their strength and fatigue resistance, and most preferably slits or arcs are used which causes edges to be engaged and supported on faces of the sheet material on opposite sides of the slits or arcs. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line. Several slit embodiments suitable for producing edge-to-face engagement support and precise bending are disclosed. With these teachings, forming numerous three-dimensional load-bearing structures from a two dimensional sheet are enabled. Examples of straight and curved beams, chassis, and exoskeletons are disclosed.

Precision-folded, high strength, fatigue-resistant structures and sheet therefor

A stress-bearing assembly for use in a vehicle body is disclosed. The assembly comprises a composite laminate resin-cured structure (12) made up of at least one pair of oriented fibre mats (14, 16) separated by a layer of foamed plastics (18), and at least one closed loop structure (20) attached to the composite structure. The mats preferably comprise glass fibres, carbon fibres or fabric and the composite structure advantageously constitutes the floor structure of a vehicle.

Stress-bearing assembly

An energy absorbing and distributing side impact system for use with a vehicle is provided, the system utilizing a collapsible side sill assembly along with multiple vehicle cross-members to achieve the desired level of vehicle side impact resistance, the combination of these elements absorbing and distributing the impact load throughout the vehicle structure The collapsible side sill assembly includes a side sill insert, the insert divided into a collapsible portion designed to absorb impact energy and a reacting portion designed to distribute the impact energy to the vehicle cross-members

System for Absorbing and Distributing Side Impact Energy Utilizing a Side Sill Assembly with a Collapsible Sill Insert

A vehicle assembling method includes the steps of assembling a lower body shell a including underbody portion having a front floor and front body portion, assembling an upper body shell, including a roof member and right and left body side panels, and assembling the upper body shell and the lower body shell, moving rearward the lower body shell relative to the upper body shell, and engaging transverse opposite side ends of the lower body shell with lower end portions of the upper body shell to join the lower body shell with the upper body shell. The under body portion can be readily joined with the upper body shell, improving the workability of the joining operation. The structure of joint portion thereof can be simplified with a desirable sealing.

Vehicle assembling method

A vehicle assembling method comprising steps of assembling lower body shell (BL) including underbody portion (BD) having a front floor (1) and front body portion (BF), assembling upper body shell (BU) including roof member, right and left body side panels (11), and assembling the upper body shell (BU) and the lower body shell (BL), moving rearward the lower body shell (BL) relative to the upper body shell (BU), engaging transverse opposite side ends of the lower body shell (BL) with lower end portions of the upper body shell (BU) to join the lower body shell (BL) with the upper body shell (BU). The under body portion (BD) can be readily joined with the upper body shell (BU) improving the workability of the joining. The structure of joint portion thereof can be simplified with a desirable sealing.

Vehicle assembling method and vehicle body structure

A vehicle transfer system for use in a vehicle assembly line comprises a first conveyor which transfers a vehicle while supporting the vehicle on its chassis with the tires being floated, and a second conveyor which transfers the vehicle body while supporting the vehicle on its tires. A ride-over table is disposed between the first and second conveyors so that the tires of the vehicle are caused to ride over the ride-over table and the chassis is lifted away from the vehicle supporting table of the first conveyor. A movable receiving table is disposed on the receiving side of the second conveyor to be movable back and forth in parallel to the second conveyor and is moved forward in synchronization with the first conveyor. The movable receiving table is further movable between a raised position in which it lifts the vehicle riding over the ride-over table before the vehicle reaches the delivery side end of the ride-over table and a lowered position in which it lowers the vehicle passing over the ride-over table onto the second conveyor.

Masamiti Kogai

Papers

Vehicle assembling method

Vehicle assembling method and vehicle body structure

Vehicle transfer system

Fahrzeugmontageverfahren und Fahrzeugkarosserie.