A structural reinforcement device for insertion into a cavity of a structure and method for making the same including a first reinforcement section that has at least one projection of a first expandable polymeric material secured to it; and a separate second reinforcement section mated with the first reinforcement section, the second reinforcement section being configured to include at least one cavity, into which the at least one projection penetrates upon mating, and at least one aperture defined therein through which the expandable material flows during expansion and where it will remain upon curing of the material, thereby causing the first reinforcement section to be coupled with the second reinforcement section.

An energy absorbing structure of a vehicle of the present invention has: a bumper reinforcement positioned at a vehicle front end portion or a vehicle rear end portion, the bumper reinforcement extending in a vehicle transverse direction; and a crash box made of a fiber-reinforced resin, the crash box being disposed at a side opposite a side of input of collision load to the bumper reinforcement, and the crash box being structured to include a crash box main body having a closed cross-sectional structure. An upper portion and a lower portion of the crash box main body do not overlap the bumper reinforcement as seen from a vehicle longitudinal direction.

An energy absorbing assembly includes a beam that extends in a first direction, a structural member that extends in a second direction transverse to the beam, a load transfer structure that restrains motion of the beam relative to the structural member by transferring lateral loads between the beam and the structural member, and a recess defined in the structural member. The beam is connected to the structural member within the recess and extends out of the recess. The beam is configured to shorten during an impact to define a failed portion of the beam, and the beam is connected to the structural member such that the failed portion of the beam is at least partially receivable in the recess.

An outrigger includes a web, an upper flange extending transversely from an upper edge of the web, a lower flange extending transversely from a lower edge of the web, and a mounting flange extending transversely from a first end of the web, a first end of the upper flange, and a first end of the lower flange. The web includes first, second, and third portions, neither of which is co-planar with any other of which.

A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.

A vehicle energy absorption structure includes an energy absorption member made of fiber reinforced resin. At least part, in a thickness direction, of that wall extending in a load input direction of the energy absorption member is provided with a plurality of discontinuous portions discontinued from each other in the load input direction, the plurality of discontinuous portions being arranged along the load input direction.

A vehicle body has an underbody structure and an auxiliary frame fastened thereto, which supports components of a wheel axis of the vehicle. The auxiliary frame is connected to the underbody structure without interposition of elastomer bearings or the like by use of several adhesive beads. The adhesive beads are configured not only with regard to a connection that meets mechanical requirements, but in particular with regard to the thickness the adhesive beads are also configured for acoustic insulation. The auxiliary frame is additionally supported on a securing structure provided below the auxiliary frame with the interposition of an acoustic insulation layer. The securing structure is connected to the underbody structure in a force-fit or material fit manner. In the receiving area of the auxiliary frame, the underbody structure can be configured with a trough-shape having lead-in chamfers for the auxiliary frame, wherein, in a way, the securing structure constitutes a cover for the receiving trough of the underbody structure.

An underbody stiffening and covering module is provided, which has a flat, non-load-bearing covering component made from a plastic material. At least one reinforcing strut is connected firmly to the covering component, the reinforcing strut extends along a predetermined load path and has a respective connection device on its end sections, with which, together with the covering component, is able to be connected to a predetermined underbody section at force application points.

A frame structure for a motor vehicle body includes at least two profile components and a connecting node, which connects the profile components with each other. At least one of the profile components has at least one console which is made of fiber reinforced plastic and on which other components can be fastened or supported.

A lateral energy absorption system includes a first carbon structure. The first carbon structure includes a first plurality of carbon tubes. The first plurality of carbon tubes have a first end with a first width and a second end with a second width. The first plurality of carbon tubes define a first taper between the second end and the first end that facilitates crumpling of the first plurality of carbon tubes during an impact. A first plurality of carbon flanges connects the carbon tubes together.