Vehicle structure assembly with strut cap

Abstract

The present disclosure provides a vehicle structure assembly with a strut cap. A structural assembly for a vehicle includes a cast body, a left apron, a right apron, a left mounting feature, a right mounting feature, a left strut cap, and a right strut cap. The left apron is fixed to the left upper side member and defines a first opening extending therethrough. The right apron is fixed to the right upper side member and defines a second opening extending therethrough. The left mounting feature extends at least partially around a first perimeter of the first opening. The right mounting feature extends at least partially around a second perimeter of the second opening. The left strut cap is secured to the left mounting feature such that the left strut cap covers the first opening. The right strut cap is secured to the right mounting feature such that the right strut cap covers the second opening.

Description

Technical Field

[0001] The present disclosure relates to a vehicle structural assembly having a pillar cap. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] A vehicle structure can be manufactured using a casting process (which involves filling a mold with a molten or semi-solid material and then hardening the material into a shape defined by the mold). A vehicle structure manufactured using a casting process can be attached to other components or parts of the vehicle. The present disclosure addresses the manufacturing of a vehicle structure attached to other components of the vehicle using a casting process. Summary of the Invention

[0004] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0005] In one form, the present disclosure provides a structural assembly for a vehicle, the structural assembly comprising a cast body, a left skirt panel, a right skirt panel, a left mounting feature, a right mounting feature, a left pillar cap, and a right pillar cap. The cast body comprises a left upper longitudinal rail and a right upper longitudinal rail. The left skirt panel is secured to the left upper longitudinal rail and defines a first opening extending therethrough. The right skirt panel is secured to the right upper longitudinal rail and defines a second opening extending therethrough. The left mounting feature extends at least partially around a first perimeter of the first opening. The right mounting feature extends at least partially around a second perimeter of the second opening. The left pillar cap is configured to receive a left pillar of a vehicle suspension system and is secured to the left mounting feature such that the left pillar cap covers the first opening. The right pillar cap is configured to receive a right pillar of the vehicle suspension system and is secured to the right mounting feature such that the right pillar cap covers the second opening.

[0006] In a variation of the structural assembly of the previous paragraph that can be implemented individually or in any combination: the cast body further includes a left lower longitudinal beam and a right lower longitudinal beam; the left pillar cap is positioned between the left upper longitudinal beam and the left lower longitudinal beam, and the right pillar cap is positioned between the right upper longitudinal beam and the right lower longitudinal beam; the left lower longitudinal beam is positioned more outboard than the left upper longitudinal beam, and the right lower longitudinal beam is positioned more outboard than the right upper longitudinal beam; the left pillar cap includes a first flange fixed to the left upper longitudinal beam, and the right pillar cap includes a second flange fixed to the right upper longitudinal beam; the left pillar cap includes: a first interface portion, The first interface portion is configured to engage the left pillar; and a first main body portion, the first main body portion extends downward from the first interface portion and is fixed to the left mounting feature, and the first flange extends from the first main body portion; the right pillar cap includes: a second interface portion, the second interface portion is configured to engage the right pillar; and a second main body portion, the second main body portion extends downward from the second interface portion and is fixed to the right mounting feature, and the second flange extends from the second main body portion; the left pillar cap includes: a first interface portion, the first interface portion a portion configured to engage the left pillar; and a first body portion, the first body portion extending downwardly from the first interface portion and fixed to the left mounting feature; the right pillar cap comprising: a second interface portion, the second interface portion configured to engage the right pillar; and a second body portion, the second body portion extending downwardly from the second interface portion and fixed to the right mounting feature; the first interface portion is above the left upper longitudinal beam, and the second interface portion is above the right upper longitudinal beam; the left mounting feature is a left flange extending upwardly from the first periphery of the first opening, and the right mounting feature is a right flange extending upwardly from the second periphery of the second opening; the left pillar engages the left pillar cap and the right pillar engages the right pillar cap; the left upper longitudinal beam includes a first end proximate the rear end of the casting body and a second end proximate the front end of the casting body, the left upper longitudinal beam being a continuous structure from the first end to the second end; and the right upper longitudinal beam includes a third end proximate the rear end of the casting body and a fourth end proximate the front end of the casting body, the right upper longitudinal beam being a continuous structure from the third end to the fourth end.

[0007] In another embodiment, the present disclosure provides a structural assembly for a vehicle, the structural assembly comprising a cast body, a left pillar cap, and a right pillar cap. The cast body comprises a left upper longitudinal member, a right upper longitudinal member, a left skirt panel, a right skirt panel, a left mounting flange, and a right mounting flange. The left skirt panel extends from the left upper longitudinal member and defines a first opening extending therethrough. The right skirt panel extends from the right upper longitudinal member and defines a second opening extending therethrough. The left mounting flange extends at least partially around a first perimeter of the first opening and extends upward from the first perimeter of the first opening. The right mounting flange extends at least partially around a second perimeter of the second opening and extends upward from the second perimeter of the second opening. The left pillar cap is configured to receive a left pillar of a vehicle suspension system and is secured to the left mounting flange. The right pillar cap is configured to receive a right pillar of the vehicle suspension system and is secured to the right mounting flange. The left pillar cap includes a first interface portion configured to engage the left pillar, and the right pillar cap includes a second interface portion configured to engage the right pillar. The first interface portion is located above the left upper longitudinal beam, and the second interface portion is located above the right upper longitudinal beam.

[0008] In a variation of the structural assembly of the previous paragraph that can be implemented individually or in any combination: the cast body also includes a left lower longitudinal beam and a right lower longitudinal beam, the left skirt panel extends from the left upper longitudinal beam to the left lower longitudinal beam, and the right skirt panel extends from the right upper longitudinal beam to the right lower longitudinal beam; the left pillar cap is positioned between the left upper longitudinal beam and the left lower longitudinal beam, and the right pillar cap is positioned between the right upper longitudinal beam and the right lower longitudinal beam; the left pillar cap includes a first attachment flange fixed to the left upper longitudinal beam, and the right pillar cap includes a second attachment flange fixed to the right upper longitudinal beam; the left pillar cap includes a first main body portion, the first main body portion extends downward from the first interface portion and is fixed to The left mounting flange, the first attachment flange extends from the first main body part; the right pillar cap includes a second main body part, the second main body part extends downward from the second interface part and is fixed to the right mounting flange, the second attachment flange extends from the second main body part; the left upper longitudinal beam includes a first end near the rear end of the casting body and a second end near the front end of the casting body, the left upper longitudinal beam is a continuous structure from the first end to the second end; and the right upper longitudinal beam includes a third end near the rear end of the casting body and a fourth end near the front end of the casting body, the right upper longitudinal beam is a continuous structure from the third end to the fourth end.

[0009] A method of forming a structural assembly for a vehicle includes casting a body including a left upper longitudinal member, a right upper longitudinal member, a left skirt panel, and a right skirt panel, wherein the left skirt panel extends from the left upper longitudinal member and the right skirt panel extends from the right upper longitudinal member; forming a first opening in the left skirt panel and a second opening in the right skirt panel; securing a left pillar cap to the left skirt panel such that the left pillar cap covers the first opening; and securing a right pillar cap to the right skirt panel such that the right pillar cap covers the second opening.

[0010] In a variation of the method of the above paragraphs, which may be implemented individually or in any combination: the method further includes securing a left pillar to the left pillar cap and securing a right pillar to the right pillar cap; and the left pillar cap is further secured to the left upper longitudinal beam, and the right pillar cap is further secured to the right upper longitudinal beam.

[0011] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order that the present disclosure may be better understood, various forms of the present disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0013] Figure 1 is a perspective view of a portion of a vehicle body including a structural assembly according to the principles of the present disclosure;

[0014] Figure 2 yes Figure 1 a perspective view of the structural assembly;

[0015] Figure 3 yes Figure 1 Exploded view of the structural assembly;

[0016] Figure 4 yes Figure 1 a side view of the structural assembly;

[0017] Figure 5 yes Figure 1 a side view of the structural assembly with suspension components removed for clarity;

[0018] Figure 6A yes Figure 1 a top perspective view of a pillar cap of the structural assembly;

[0019] Figure 6B yes Figure 1 a bottom perspective view of a strut cap of the structural assembly; and

[0020] Figure 7Is used to make Figure 1 Flowchart of a method of structural assembly.

[0021] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0022] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0023] refer to Figure 1 , a vehicle 12 including a structural assembly 10 is provided. In the example shown, the vehicle 12 is of unibody construction. In some forms, the vehicle 12 may be a body-on-frame split architecture. In some forms, the vehicle 12 may be an electric vehicle. In other forms, the vehicle 12 may have an internal combustion engine (ICE). Still further, in other forms, the vehicle 12 may be a hybrid electric vehicle (HEV). The structural assembly 10 according to the present disclosure includes a casting or cast body 14 and a pair of strut caps 18a, 18b secured to the casting 14, as described in more detail below.

[0024] As used herein, a "casting" 14 is a product manufactured by a casting process (i.e., by filling a molten or semi-solid material into a mold and then hardening the material into a shape defined by the mold). The casting 14 includes a plurality of structural components that are joined together in a casting process. The plurality of structural components form a structural load path and extend in multiple directions in 3D space. That is, the casting process provides the casting 14 with a deformation and energy absorption pattern throughout the 3D space, which is easier to absorb energy than forming each component separately and joining them together later. By forming the casting 14 using a casting process, the casting 14 increases the uniformity of the energy absorption characteristics of the entire structural component and reduces the overall weight of the portion of the hybrid structural assembly 10. The casting process reduces the machining of the structural components when forming the casting 14.

[0025] The casting 14 is formed from a castable alloy material (i.e., a material that can be used in a casting process). As described above, the material used in the casting process is heated to a liquid phase or a semi-solid phase and then introduced into a mold to form the casting 14. The castable alloy material can be, for example, one of an aluminum alloy, fiber-reinforced aluminum, fiber-reinforced magnesium, etc. The castable alloy material can have a lower weight, ductility, and / or toughness than other materials used in vehicle components. In other words, the ductility of the castable alloy material may be less and may have lower toughness than other materials that cannot be used in the casting process. The lower weight of the castable alloy reduces the overall weight of the vehicle 12.

[0026] refer to Figure 2 and Figure 3 , the casting 14 can be the front end of the vehicle 12 and can be fixed to the subframe (not shown) of the vehicle 12 so that the subframe is supported by the casting 14. In certain collision events, the subframe can transfer energy from the subframe to the casting 14. In the example shown, the casting 14 includes a front fascia cross member 30, a pair of opposing beams or inner longitudinal beams 32a, 32b, a pair of opposing upper longitudinal beams 34a, 34b, and a pair of opposing skirt panels 36a, 36b. The bumper (not shown) extends in a transverse direction relative to the longitudinal direction of the vehicle 12 and is fixed to the front ends of the pair of beams 32a, 32b. The front fascia cross member 30 extends in a transverse direction at the rear end 39a of the casting 14 and is connected to the intermediate inner longitudinal beams 32a, 32b and the subframe (not shown). Each beam 32a, 32b extends from the lower portion of the corresponding hinge pillar to the bumper. Each beam 32a, 32b is also curved and extends around the front wheels (not shown) of the vehicle 12 and forms a portion of the corresponding front wheel well. Upper longitudinal beams 34a, 34b are positioned above the beams 32a, 32b and extend from the upper portion of the corresponding hinge pillar to the front end of the corresponding beam 32a, 32b. In other words, each upper longitudinal beam 34a, 34b includes a first end 42a located at the upper portion of the corresponding hinge pillar and a second end 42b located at the front end of the corresponding beam 32a, 32b. It should be understood that each upper longitudinal beam 34a, 34b has a continuous structure from the first end 42a to the second end 42b.

[0027] refer to Figures 2 to 4 Each skirt panel 36a, 36b is arcuate and extends from the corresponding upper longitudinal beam 34a, 34b to the corresponding beam 32a, 32b. In other words, each skirt panel 36a, 36b extends from the lower inner side of the corresponding upper longitudinal beam 34a, 34b to the upper outer side of the corresponding beam 32a, 32b. In this manner, each skirt panel 36a, 36b is positioned between the corresponding upper longitudinal beam 34a, 34b and the corresponding beam 32a, 32b. Each skirt panel 36a, 36b also extends from the rear end 39a of the casting 14 to the front end 39b of the casting 14 and includes an opening 48 ( Figure 3 ). That is, the opening 48 ( Figure 3 ) extends through each skirt panel 36a, 36b so that one or more components 50 ( Figure 4) may extend through (or through) the opening 48. In the example shown, the opening 48 formed in the skirt panels 36a, 36b is closer to the respective upper longitudinal rails 34a, 34b than the respective rails 32a, 32b. In some forms, the opening 48 formed in the skirt panels 36a, 36b may be closer to the respective beams 32a, 32b than the respective upper longitudinal rails 34a, 34b. In other forms, the opening 48 formed in the skirt panels 36a, 36b may be located at a midpoint between the respective rails 32a, 32b and the respective upper longitudinal rails 34a, 34b. In the example shown, each skirt panel 36a, 36b includes a mounting feature or flange 52 ( Figure 3 ), which will be described in more detail below. In the example shown, the mounting feature 52 extends upwardly from the skirt panels 36a, 36b and extends at least partially around the opening 48 in the skirt panels 36a, 36b.

[0028] Each strut cap 18a, 18b is secured to a mounting feature 52 of a corresponding skirt panel 36a, 36b of the casting 14 and houses at least a portion of a vehicle suspension system 60. The vehicle suspension system 60 provides a smooth ride by absorbing energy from various road bumps while driving. The vehicle suspension system 60 includes various components, such as control arms, springs, shock absorbers, struts, and ball joints. In the example shown, each strut cap 18a, 18b is secured to the mounting feature 52 so that the strut cap 18a, 18b covers the opening 48. Each strut cap 18a, 18b can be secured to the mounting feature 52 by welding, mechanical fasteners, and / or any other suitable attachment means.

[0029] refer to Figure 4 、 Figure 5 、 Figure 6A and Figure 6B Each support cap 18a, 18b can be manufactured using a stamping process or a casting process, for example. Figure 6A and Figure 6BAs shown, each pillar cap 18a, 18b includes a main body portion 54, a flange 56 and an interface portion 58. In the example shown, the main body portion 54 extends around the entire periphery of the interface portion 58. In some forms, the main body portion 54 extends at least partially around the periphery of the interface portion 58. The main body portion 54 includes an angled section 54a and a mounting section 54b. The angled section 54a extends downward and outward from the interface portion 58 to the mounting section 54b. In one form, the mounting section 54b can be vertically oriented or otherwise extend vertically. In other forms, the mounting section 54b can be angled. The mounting section 54b extends downward from the angled section 54a and is fixed to the mounting feature 52. The mounting section 54b is positioned near the lower end 62a of the main body portion 54 (i.e., the lower end 62a of the main body portion 54 is near the mounting feature 52) and has an area greater than the area of ​​the upper end 62b of the main body portion 54 (i.e., the upper end 62b of the main body portion 54 extends from the interface portion 58).

[0030] A flange 56 extends from the main body portion 54 and is secured to the upper longitudinal rails 34a, 34b of the casting 14 by welding, mechanical fasteners, and / or any other suitable attachment means. In the example shown, the flange 56 extends at least partially around the mounting section 54b of the main body portion 54. In some forms, the flange 56 may extend from the angled section 54a of the main body portion 54 and may be secured to the upper longitudinal rails 34a, 34b of the casting 14. In the example shown, the flange 56 has a predetermined shape (e.g., an L-shape) corresponding to a portion of the upper longitudinal rails 34a, 34b. In this manner, the strut caps 18a, 18b are also secured to the upper longitudinal rails 34a, 34b and extend along a portion of the length of the upper longitudinal rails 34a, 34b. In one form, the flange 56 may include a hole 57 extending therethrough for securing the flange 56 to the upper longitudinal rails 34a, 34b.

[0031] The interface portion 58 is positioned above the upper longitudinal beams 34a, 34b ( Figure 4 and Figure 5 ) and is configured to engage component 50 of a vehicle suspension system 60. Interface portion 58 includes a hole 64 extending therethrough. In this manner, a portion of component 50 can extend through hole 64. In the example shown, hole 64 is located at or near a central area of ​​interface portion 58. Hole 59 can be formed in body portion 54 and / or interface portion 58 and can include a circular or oval shape. The diameter of hole 59 can be smaller than the diameter of hole 64. Hole 59 can facilitate securing strut caps 18a, 18b to casting 14 and / or component 50 of suspension system 60.

[0032] In the example shown, component 50 is a MacPherson strut secured at a first end to a wheel hub (not shown) and at a second end to a respective strut cap 18a, 18b. For example, each strut cap 18a, 18b may house a strut of a vehicle suspension system.

[0033] refer to Figure 7 , discloses manufacturing the structural assembly 10 of the present disclosure. At 604, a casting 14 is manufactured, the casting including the front fascia cross member 30, a pair of opposing beams or inner longitudinal beams 32a, 32b, a pair of opposing upper longitudinal beams 34a, 34b, and a pair of opposing skirt panels 36a, 36b. In some forms, the opposing skirt panels 36a, 36b may be manufactured separately from the casting 14 and secured to the casting 14. In one form, the opposing skirt panels 36a, 36b may be manufactured by a stamping process and then secured to the casting 14. At 604, openings 48 are formed in the skirt panels 36a, 36b. In one form, the casting 14 is trimmed or cut to form the openings 48 in the skirt panels 36a, 36b. In another form, the casting 14 is manufactured to include the openings 48 therein. At 612, the strut caps 18a, 18b are secured to the casting 14 using welding, mechanical fasteners, or any other suitable attachment means. It should be understood that the strut caps 18a, 18b can be manufactured separately from the casting 14 and secured to the casting 14. In one example, the strut caps 18a, 18b are manufactured using a stamping process. In another form, the opposing skirts 36a, 36b can be manufactured as a separate casting along with the strut caps and secured to the casting 14. At 616, the component 50 of the suspension system 60 is secured to the strut caps 18a, 18b.

[0034] The structural assembly 10 of the present disclosure provides a front end architecture comprising strut caps 18a, 18b manufactured separately from and secured to the casting 14. In some forms, the structural assembly 10 of the present disclosure provides a front end architecture comprising strut caps 18a, 18b and opposing skirts 36a, 36b manufactured separately from and joined to the casting 14. In this way, the front end architecture can be employed with, for example, a MacPherson strut suspension without casting issues. That is, employing the height of a MacPherson strut suspension in a single cast component comprising the strut caps and opposing skirts may introduce casting feasibility issues where portions of the interface of the shock absorber to the structure would be die-locked behind the opposing upper longitudinal beams. Manufacturing the strut caps separately from the main casting and joining them using a separate process provides a solution to the problem of the interface of the shock absorber to the structure being die-locked.

[0035] Unless otherwise expressly indicated herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics when describing the scope of the present disclosure should be understood as modified by the word "about" or "approximately." Such modification is desirable for various reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0036] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical "or", and should not be construed to mean "at least one of A, at least one of B, and at least one of C."

[0037] The description of the present disclosure is merely exemplary in nature and, thus, variations that do not depart from the essence of the disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.

[0038] According to the present invention, a structural assembly for a vehicle is provided, the structural assembly having: a cast body, the cast body including: a left upper longitudinal beam and a right upper longitudinal beam; a left skirt panel and a right skirt panel, wherein the left skirt panel extends from the left upper longitudinal beam and defines a first opening extending therethrough, and the right skirt panel extends from the right upper longitudinal beam and defines a second opening extending therethrough; and a left mounting flange and a right mounting flange, wherein the left mounting flange extends at least partially around a first periphery of the first opening, the left mounting flange extends upward from the first periphery of the first opening, and wherein the right mounting flange at least partially around a first periphery of the second opening. The left pillar cap is configured to receive a left pillar of a vehicle suspension system and is fixed to the left mounting flange, the right pillar cap is configured to receive a right pillar of the vehicle suspension system and is fixed to the right mounting flange, the left pillar cap includes a first interface portion configured to engage the left pillar, and the right pillar cap includes a second interface portion configured to engage the right pillar, the first interface portion is located above the left upper longitudinal beam, and the second interface portion is located above the right upper longitudinal beam.

[0039] According to one embodiment, the cast body further comprises a left lower longitudinal beam and a right lower longitudinal beam, and wherein the left skirt panel extends from the left upper longitudinal beam to the left lower longitudinal beam, and the right skirt panel extends from the right upper longitudinal beam to the right lower longitudinal beam.

[0040] According to one embodiment, the left pillar cap is positioned between the left upper longitudinal beam and the left lower longitudinal beam, and wherein the right pillar cap is positioned between the right upper longitudinal beam and the right lower longitudinal beam.

[0041] According to one embodiment, the left pillar cap includes a first attachment flange secured to the left upper longitudinal member, and wherein the right pillar cap includes a second attachment flange secured to the right upper longitudinal member.

[0042] According to one embodiment, the left pillar cap includes a first main body portion, which extends downward from the first interface portion and is fixed to the left mounting flange, and the first attachment flange extends from the first main body portion; and the right pillar cap includes a second main body portion, which extends downward from the second interface portion and is fixed to the right mounting flange, and the second attachment flange extends from the second main body portion.

[0043] According to one embodiment, the left upper longitudinal beam includes a first end close to the rear end of the casting body and a second end close to the front end of the casting body, and the left upper longitudinal beam is a continuous structure from the first end to the second end; and the right upper longitudinal beam includes a third end close to the rear end of the casting body and a fourth end close to the front end of the casting body, and the right upper longitudinal beam is a continuous structure from the third end to the fourth end.

Claims

1. A structural assembly for a vehicle, comprising: A casting body, the casting body comprising a left upper longitudinal beam and a right upper longitudinal beam; a left skirt panel and a right skirt panel, wherein the left skirt panel is secured to the left upper longitudinal member and defines a first opening extending therethrough, wherein the right skirt panel is secured to the right upper longitudinal member and defines a second opening extending therethrough; and a left mounting feature and a right mounting feature, wherein the left mounting feature extends at least partially around a first perimeter of the first opening, wherein the right mounting feature extends at least partially around a second perimeter of the second opening; as well as a left strut cap and a right strut cap, wherein the left strut cap is configured to receive a left strut of a vehicle suspension system and is secured to the left mounting feature such that the left strut cap covers the first opening, and wherein the right strut cap is configured to receive a right strut of the vehicle suspension system and is secured to the right mounting feature such that the right strut cap covers the second opening. 2 . The structural assembly according to claim 1 , wherein the cast body further comprises a left lower longitudinal beam and a right lower longitudinal beam. 3 . The structural assembly of claim 2 , wherein the left pillar cap is positioned between the left upper and left lower longitudinal members, and wherein the right pillar cap is positioned between the right upper and right lower longitudinal members. 4 . The structural assembly of claim 2 , wherein the left skirt panel extends from the left upper longitudinal member to the left lower longitudinal member, and the right skirt panel extends from the right upper longitudinal member to the right lower longitudinal member. 5 . The structural assembly of claim 2 , wherein the left lower longitudinal member is positioned more outboard than the left upper longitudinal member, and wherein the right lower longitudinal member is positioned more outboard than the right upper longitudinal member. 6 . The structural assembly of claim 1 , wherein the left pillar cap includes a first flange secured to the left upper longitudinal member, and wherein the right pillar cap includes a second flange secured to the right upper longitudinal member.

7. The structural assembly according to claim 6, wherein: The left pillar cap includes a first interface portion configured to engage the left pillar; and a first body portion extending downwardly from the first interface portion and secured to the left mounting feature, the first flange extending from the first body portion; and The right pillar cap includes a second interface portion configured to engage the right pillar and a second body portion extending downwardly from the second interface portion and secured to the right mounting feature, the second flange extending from the second body portion.

8. The structural assembly according to claim 1, wherein: The left pillar cap includes a first interface portion configured to engage the left pillar; and a first body portion extending downwardly from the first interface portion and secured to the left mounting feature; and The right pillar cap includes a second interface portion configured to engage the right pillar and a second body portion extending downwardly from the second interface portion and secured to the right mounting feature. 9 . The structural assembly of claim 8 , wherein the first interface portion is located above the left upper longitudinal member, and the second interface portion is located above the right upper longitudinal member.

10. The structural assembly of claim 1, wherein the left mounting feature is a left flange extending upward from the first perimeter of the first opening, and wherein the right mounting feature is a right flange extending upward from the second perimeter of the second opening.

11. The structural assembly of claim 1 further comprising said left strut engaging said left strut cap and said right strut engaging said right strut cap.

12. The structural assembly according to claim 1, wherein: The left upper longitudinal beam includes a first end close to the rear end of the casting body and a second end close to the front end of the casting body, and the left upper longitudinal beam is a continuous structure from the first end to the second end; and The right upper longitudinal beam includes a third end close to the rear end of the casting body and a fourth end close to the front end of the casting body, and the right upper longitudinal beam is a continuous structure from the third end to the fourth end.

13. A method of forming a structural assembly for a vehicle, the method comprising: a cast body comprising a left upper longitudinal beam, a right upper longitudinal beam, a left skirt panel, and a right skirt panel, wherein the left skirt panel extends from the left upper longitudinal beam and the right skirt panel extends from the right upper longitudinal beam; forming a first opening in the left skirt panel and forming a second opening in the right skirt panel; securing a left pillar cap to the left skirt panel so that the left pillar cap covers the first opening; as well as A right pillar cap is secured to the right skirt panel such that the right pillar cap covers the second opening.

14. The method of claim 13, further comprising securing a left strut to the left strut cap and securing a right strut to the right strut cap. 15 . The method of claim 13 , wherein the left pillar cap is further secured to the left upper longitudinal member, and the right pillar cap is further secured to the right upper longitudinal member.

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