Vehicle roof structure with integrated electrical connectivity module and methods for making the same are disclosed. For one example, the vehicle roof structure includes a plurality of pre-assembled components and an electrical connectivity module. The pre-assembled components include a plastic panel which covers a first compartment integrated into the roof structure that houses the electrical connectivity module below the plastic panel. The electrical connectivity module can be coupled to an antenna system that provides radio or cellular communications. The antenna system can be attached to the plastic panel. The electrical module can include a plurality of modems that can receive and transmit radio or cellular signals. An advanced driver assistance systems (ADAS) module can be housed in a second compartment integrated into the roof structure. The roof structure including the electrical connectivity module or ADAS module can be attached to a body frame of a vehicle. The plastic panel protects the electrical connectivity module while not creating a barrier for radio or cellular communications of the antenna system. The roof structure can be an aluminum roof structure, a fixed full glass roof structure, a fixed half glass roof structure or a movable sun structure.

A rear deck post assembly is provided for reinforcing a cargo bed of a utility vehicle. The assembly includes a first deck mount coupled to a vehicle frame, and a first rear deck post coupled to the first deck mount. A second deck mount is provided coupled to the vehicle frame and spaced apart from the first deck mount. A second rear deck post is coupled to the second deck mount. A deck sill component is provided longitudinally extending between the first deck post and the second deck post. Deck bolts may be used to couple the deck sill component, deck mounts, and deck posts to the vehicle frame. The first and second deck mounts and deck posts may be a cast aluminum alloy, a cast magnesium alloy, or a fiber reinforced composite material.

A system and method for fabricating a vehicle structure includes a first portion and a second portion having a body cooperating with the first portion using an additive manufacturing process. The body of the second portion includes one or more projections extending from the body. A third portion includes at least one opening and operatively engages the one or more projections of the second portion.

There is provided a composite structure, comprising a base member(s) made of metallic material, and a reinforcement member(s) made of fiber reinforced plastic including reinforcement fibers which are aligned in a uni-direction, wherein at least one slit is formed on the reinforcement member(s) so as to extend in an orientation direction of the reinforcement fibers.

A plurality of metallic bulkheads fixed at predetermined intervals inside a side sill includes a partition wall portion partitioning an inner space of the side sill and a bonding flange portion formed to surround an outer periphery of the partition wall portion and bonded to an inner surface of the side sill and has an I-shaped cross-section. The partition wall portion of one bulkhead fixed to an upper curved portion is disposed to be substantially parallel to a radial direction passing through a curved center of the upper curved portion such that the partition wall portion is propped to prevent the upper curved portion from being crushed when a collision load in a front and rear direction is input to a pillar portion of the side sill to prevent the collapse deformation of the pillar portion.

A reinforcing steel member for a motor vehicle of the present invention includes a steel sheet, a first resin material disposed on at least a part of a surface of the steel sheet, and a second resin material disposed on at least a part of a surface of the first resin material and having a matrix resin and a reinforcing fiber material contained in the matrix resin, in which in a cross section of the first resin material and the second resin material perpendicular to the surface of the steel sheet, between one end portion of the second resin material and the other end portion of the second resin material, there is a portion having a length of 80 mm or more along a boundary between the second resin material and the first resin material, in the first resin material, a protrusion portion having a length X of 3.0 mm or more from the two end portions of the second resin material to an end portion of the first resin material is formed in the cross section, and a Young's modulus of the first resin material at room temperature is 1/10 or less of a Young's modulus of the second resin material at room temperature.

A vehicle coupling, and a method for the manufacture thereof, having a coupling body (1) and at least one structural element (2) placed thereon wherein the structural element (2) is force fit to the coupling body (1) using a bulk plastic material (3).

An axle carrier for a motor vehicle is disclosed having at least two attachment points, a metallic upper shell and a lower shell of fiber composite material coupled to the metallic upper shell. A first load path extending through the metallic upper shell between the at least two attachment points in an edge region, and a second load path shorter that the first load path extending through the lower shell.

A vehicle body includes a structural member having an inner surface defining an elongated cavity. The structural member includes an outer panel member joined to an inner panel member. A reinforcement member is positioned in the cavity wherein a gap is provided between the reinforcement member and the inner surface of the structural member. The reinforcement member includes an outer section, an inner section and a tension web interposed between and contacting the outer section and inner section. The outer section faces the outer panel member and the inner section faces the inner panel member. The tension web is secured to the outer panel member and inner panel member. An adhesive secured to the reinforcement member is activatable to expand toward the inner surface of the structural member to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.

A vehicle roof stiffener includes a metal or metal alloy frame defining a central opening and at least one corner. The vehicle roof stiffener also includes a fiber reinforced polymer (FRP) portion including at least one transition structure comprising a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The FRP portion is located in the at least one corner. In some examples, the frame includes an opening in the at least one corner, and the FRP portion spans the opening. In other examples, the FRP portion overlaps the frame at the at least one corner. The FRP portion located at the corner may improve rigidity of the roof stiffener to increase resistance to a racking motion and increase the overall stiffness of the vehicle.