This disclosure relates to a motor vehicle, and in particular a vehicle body structure for a motor vehicle, with an extended roof reinforcement structure. An example vehicle includes an A-pillar, a roof side rail, a dash panel, and a reinforcement structure extending at least partially through the roof side rail and the A-pillar to a front end forward of the dash panel.

A vehicle floor assembly having a floor panel and a pair of elongated members disposed along opposing sides of the floor panel. A central tunnel extends longitudinally between the pair of elongated members and has an upper surface elevated vertically from a planar extent of the floor panel. A crossmember beam is coupled to and spans between the pair of longitudinal members. The crossmember beam has a cross-sectional shape extending continuously along a length of the crossmember beam. The crossmember beam includes a curved shape along at least a section of the length of the crossmember beam that positions a lower surface of the crossmember beam above the upper surface of the central tunnel.

The invention relates to a manufacturing method for a crash frame of a battery compartment for electric drive vehicles by using metallic sheets which are arranged on top of one another and fixed together and which form in a following step a space by using an inner active media forming process to create walls of a crash frame whereby the space works as a deformation space to protect the battery modules inside the battery compartment against an impact. The invention further relates to the use of the crash frame for a battery compartment.

The invention relates to an elongate steel structure (10) for a vehicle comprising:—first steel sheet element (11), and a second steel sheet element (12), said first and second steel sheet elements constituting opposite ends of the elongate steel structure and said first and second steel sheet elements overlapping each other in a mid-portion of said elongate steel structure, wherein the first and the second steel sheet elements have an overlapping hat profile including a central portion (17), two webs (18), and two flanges (19), wherein at least one of the first and second steel sheet elements include cut-outs (13) along the flanges (19) such that the overlap is interrupted along said flanges (19).

The frame member has a flat sheet portion with a recessed portion having a pair of wall portions and a bottom portion extending between tip portions in an extending direction of the pair of wall portions, in which a Vickers hardness of a region of the flat sheet portion excluding the recessed portion is 330 Hv or more, a depth of the recessed portion is 5 mm or more, when a width of the recessed portion is L.sub.0 and a cross-sectional length of an inner peripheral wall of the recessed portion consisting of the pair of wall portions and the bottom portion is L.sub.1, a value of (L.sub.1−L.sub.0)/L.sub.0 is 0.18 or more and 2.8 or less, and a Vickers hardness of a ridgeline portion extending between the flat sheet portion and the recessed portion is 1.06 times or more and 1.20 times or less the Vickers hardness of the region of the flat sheet portion excluding the recessed portion.

A vehicle component for a vehicle has a component body which is formed from a core material. The component body has a localized deformation zone which extends flat in the core material, and the deformation zone has a locally variable tensile strength according to a predetermined tensile strength profile configured to influence a deformation profile of the component body upon a force acting on the component body.

Protection and load distribution strategies are disclosed for electrified vehicle traction battery packs. Exemplary battery protection structures may include a corrugated portion and at least one flat sheet portion that are joined together. The battery protection structure may be integrated as part of an outer enclosure assembly of the traction battery pack or could embody a skid plate design that is a separate structure from the outer enclosure assembly. The battery protection structures may be configured for absorbing and transferring energy during vehicle loading events, thereby minimizing the transfer of loads inside the battery pack where relatively sensitive battery internal components are housed.

A hybrid structural assembly for a motor vehicle includes a casting and a structural inlay. The casting includes a plurality of structural components joined together in a casting process to form structural load paths and extending in a plurality of directions in a 3D space. The casting includes a cast-allowable alloy material. The structural inlay is secured to at least one of the structural components. The structural inlay includes a material having at least one of a higher ductility and a higher toughness than the cast-allowable alloy material.

A vehicle component for a vehicle has a component body which extends longitudinally in a longitudinal direction, wherein the component body has deformation zones which are spatially distributed in the longitudinal direction and are formed in the component body of sheet metal material. At least two locally distributed and spaced-apart deformation zones have different tensile strengths configured to influence a deformation course of the component body upon a force acting on the component body.

An assembly of an aluminum-based part and a press hardened steel part provided with an alloyed coating including in weight percent, 0.1 to 15.0% silicon, 15.0 to 70% of iron, 0.1 to 20.0% of zinc, 0.1 to 4.0% of magnesium, the balance being aluminum, on at least one of the surfaces thereof placed so as to be in contact with the aluminum-based part.