Abstract:
An automotive vehicular structure includes a composite first body side outer panel including a first connecting panel and a composite second body side outer panel and a second connecting panel. The second connecting panel is directly attached to the first connecting panel at a location between the first side panel and the second side panel. A method of assembling an automotive vehicle is also provided.

Description:
BACKGROUND AND SUMMARY 
       [0001]    The present invention generally pertains to body structures for vehicles and, more particularly, to composite body structures for vehicles. 
         [0002]    A vehicle is supported by a chassis that carries various loads. The loads include an unloaded weight of the vehicle and cargo loads generated by passengers and other items added to the vehicle. The loads also include aerodynamic loads and road loads input through a suspension as the vehicle is maneuvered over a road. 
         [0003]    In some configurations, a body of the vehicle is part of the chassis. In such configurations, a structure of the body designed to carry the loads is typically composed of steel. Steel is most often employed because parts of the structure can be produced in high volume, at low cost, using conventional methods. 
         [0004]    In accordance with the present invention, an all composite automotive vehicular structure and a method of assembling an automotive vehicle are provided. In one aspect, an automotive vehicular structure includes a composite first body side outer panel and composite second body side outer panel. The first body side outer panel includes a first side panel and a first connecting panel. The first side panel extends in a substantially longitudinal direction on a first side and defines at least an entire first door opening. The first connecting panel extends from the first side panel in a first substantially transverse direction. The second body side outer panel includes a second side panel and a second connecting panel. The second side panel extends in the substantially longitudinal direction on a second side opposite the first side and defines at least an entire second door opening. The second connecting panel extends from the second side panel in a second substantially transverse direction opposite the first transverse direction. The second connecting panel is directly attached to the first connecting panel at a location between the first side panel and the second side panel. 
         [0005]    In another aspect, an automotive vehicular apparatus includes a composite floor pan, a composite structure joined to the floor pan, and a composite first outer panel joined to the floor pan and the structure. The composite floor pan includes a floor of a passenger compartment. The structure substantially surrounds at least a majority of an upper portion of the passenger compartment. The structure includes a roof member and elongated support members extending from the roof member to the floor pan. The first outer panel joined to the floor pan and the frame in a monocoque. The first outer panel is entirely composed of materials free of carbon fiber. 
         [0006]    In another aspect, an automotive vehicular structure includes a composite first body side outer panel and a composite second body side outer panel. The first body side outer panel extends in a substantially longitudinal direction on a first side. The first body side outer panel defines at least an entire first body side opening. The first body side outer panel includes (i) a first roof panel part including a first tie rail extending in a first substantially transverse direction, (ii) a first rocker panel part, (iii) a first a-pillar part connecting the roof panel part and the rocker panel part, the a-pillar part including a second tie rail extending in the first substantially transverse direction, and (iv) a first quarter panel part connecting the roof panel part and the rocker panel part, the first quarter panel part including a third tie rail extending in the first substantially transverse direction. The composite second body side outer panel extends in the substantially longitudinal direction on a second side opposite the first side and defines at least an entire second body side opening. The second body side outer panel is directly attached to the first body side outer panel at a location between the first side and the second side. In a related aspect, the second body side outer panel includes: (a) a second roof panel part including a fourth tie rail directly attached to the first tie rail at a first location, (b) a second rocker panel part, (c) a second a-pillar part connecting the second roof panel part and the second rocker panel part, the second a-pillar part including a fifth tie rail directly attached to the second tie rail at a second location, and (d) a second quarter panel part connecting the second roof panel part and the second rocker panel part, the second quarter panel part including a sixth tie rail directly attached to the third tie rail at a third location. 
         [0007]    In other aspects, an automotive vehicular structure includes a composite floor pan structure extending along a length between an a-pillar and a b-pillar, and a composite outer body structure coupled to the floor pan to create a first closed multi-sided rocker section along the length. In still other aspects, an automotive vehicular structure includes a composite underbody structure creating a first part of an a-pillar, and a composite outer body structure directly attached to the underbody structure to create a closed multi-sided a-pillar section along a length. 
         [0008]    The present invention further provides a floor pan structure for an automotive vehicle. The floor pan structure includes a composite floor, a pair of sides integral to and extending from the floor as a single piece, and a raised section extending from the floor between the sides as a single piece, the raised section providing a mounting surface for a passenger seat. 
         [0009]    In another aspect, an automotive vehicular structure includes a composite floor pan structure, a composite frame structure, and a composite outer body. The floor pan structure longitudinally extends along a length of a b-pillar and includes an integral outer side wall. The frame structure directly attaches to an outboard side of the outer side wall. The outer body structure directly attaches to the frame structure opposite the floor pan to create a closed multi-sided b-pillar section when viewed along the b-pillar. 
         [0010]    In yet another aspect, an automotive vehicular structure includes a composite floor pan structure, a composite outer body structure, and a composite frame structure. The composite floor pan structure longitudinally extends along a length of a b-pillar and includes an integral outer side wall. The outer body structure is directly attached to a first side of outer side wall to create a first closed multi-sided b-pillar section when viewed along the b-pillar. The frame structure directly attaches to an opposite second side of the outer side wall to create a second closed multi-sided b-pillar section contiguous with the first closed b-pillar section. 
         [0011]    The present automotive vehicular body structure is advantageous over other body structures. For example, the automotive vehicular structure provides an all composite monocoque structure that is of high strength and low weight. The automotive vehicular structure further provides structural sections and cross-sections, for example a-pillar, b-pillar, rocker, and floor pan sections and cross-sections. The various sections and cross-sections are created by composite panels and are advantageously resistive to impacts that occur, for example in a vehicle accident. 
         [0012]    Additional advantages and features of the present invention will be found in the following description and accompanying claims, as well as in the appended drawings. 
     
    
     
       DRAWINGS 
         [0013]      FIG. 1  is a perspective view showing a vehicle according to the present disclosure; 
           [0014]      FIG. 2  is a perspective view showing a composite body structure of the vehicle shown in  FIG. 1 ; 
           [0015]      FIG. 3  is a top view of the composite body structure shown in  FIG. 2 ; 
           [0016]      FIG. 4  is a bottom view of the composite body structure shown in  FIG. 2 ; 
           [0017]      FIG. 5  is an exploded perspective view of the composite body structure shown in  FIG. 2 ; 
           [0018]      FIG. 6  is an exploded perspective view of the composite body structure shown in  FIG. 2 ; 
           [0019]      FIG. 7  is an exploded perspective view of the composite body structure shown in  FIG. 2 ; 
           [0020]      FIG. 8  is a perspective view of an underbody sub-assembly illustrating the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0021]      FIG. 9  is a perspective view of the underbody sub-assembly illustrating the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0022]      FIG. 10  is a perspective view of the underbody sub-assembly illustrating the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0023]      FIG. 11  is a fragmentary top view of a portion of the underbody sub-assembly illustrating the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0024]      FIG. 12  is a perspective view illustrating the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0025]      FIG. 13  is a fragmentary perspective view illustrating a portion of the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0026]      FIG. 14  is a fragmentary top view illustrating a portion of the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0027]      FIG. 15  is a fragmentary top view illustrating a portion of the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0028]      FIG. 16  is a fragmentary front view of a portion of the composite body structure shown in  FIG. 2  in a partially assembled state; 
           [0029]      FIG. 17  is a rear view of the composite body structure shown in  FIG. 2  illustrating a cowl panel; 
           [0030]      FIG. 18  is a fragmentary cross-sectional view of the composite body structure taken along line  18 - 18  shown in  FIG. 3  illustrating a dash/cowl section; 
           [0031]      FIG. 19  is a fragmentary cross-sectional view of the composite body structure taken along line  19 - 19  shown in  FIG. 3  illustrating a front header section; 
           [0032]      FIG. 20  is a fragmentary cross-sectional view of the composite body structure taken along line  20 - 20  shown in  FIG. 3  illustrating a rear header section; 
           [0033]      FIG. 21  is a fragmentary cross-sectional view of the composite body structure taken along line  21 - 21  shown in  FIG. 3  illustrating a tail section; 
           [0034]      FIG. 22  is a fragmentary cross-sectional view of the composite body structure taken along line  22 - 22  shown in  FIG. 3  illustrating a rocker section; 
           [0035]      FIG. 23  is a fragmentary cross-sectional view of the composite body structure taken along line  23 - 23  shown in  FIG. 3  illustrating an a-pillar section; 
           [0036]      FIG. 24  is a fragmentary cross-sectional view of the composite body structure taken along line  24 - 24  shown in  FIG. 12  illustrating a b-pillar section; 
           [0037]      FIG. 25  is a fragmentary cross-sectional view of the composite body structure taken along line  25 - 25  shown in  FIG. 12  illustrating a b-pillar section; 
           [0038]      FIG. 26  is a fragmentary cross-sectional view of the composite body structure taken along line  26 - 26  shown in  FIG. 3  illustrating an a-pillar section; 
           [0039]      FIG. 27  is a fragmentary cross-sectional view of the composite body structure taken along line  27 - 27  shown in  FIG. 3  illustrating an a-pillar section; 
           [0040]      FIG. 28  is a fragmentary cross-sectional view of the composite body structure taken along line  28 - 28  shown in  FIG. 3  illustrating a quarter/sail section; 
           [0041]      FIG. 29  is a fragmentary cross-sectional view of a portion of the composite body structure taken along line  29 - 29  in  FIG. 4  illustrating a floor panel section; 
           [0042]      FIG. 30  is a schematic cross-sectional view illustrating a method of applying adhesive between two panels of the composite body structure shown in  FIG. 2 ; 
           [0043]      FIG. 31  is a fragmentary perspective view of a composite body panel including a honeycomb core material and a layered fiber reinforcement; 
           [0044]      FIG. 32  is a schematic view of composite material arrangements for a composite body panel; and 
           [0045]      FIG. 33  is a fragmentary side view illustrating composite body panels joined by a bolted connection. 
       
    
    
       [0046]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0047]    An embodiment of a composite body structure is illustrated in  FIGS. 1-28 . Referring to  FIG. 1 , an exemplary vehicle  10  according to the present disclosure is shown. Generally, vehicle  10  is a two door, three-wheeled electric vehicle having a front-wheel drive layout. However, it will be appreciated from the following description that the present invention is not limited to vehicles having a particular powerplant, layout, or number of wheels. For example, the present invention applies equally to vehicles having an internal combustion engine used alone or in combination with an electric machine (i.e., hybrid vehicles) to provide drive torque. The present invention also applies equally to front-wheel drive and rear-wheel drive vehicles. 
         [0048]    Vehicle  10  includes a front-end module  20 , a rear-end module  22 , and a composite body structure  24 . Vehicle  10  further includes various body closures, including doors  30 ,  32 , a rear hatch  34 , a windshield  36 , rear side glass  38 ,  40 , and a roof panel  42 . Together, front-end module  20 , rear-end module  22 , and body structure  24  serve as a chassis of vehicle  10 . In particular, front-end module  20 , rear-end module  22 , and body structure  24  provide the structure that supports vehicle  10 . Together, body structure  24  and the body closures define a passenger compartment  44  within vehicle  10 . 
         [0049]    Front-end module  20  includes a front-end structure  50 , a front suspension  52 , an electric motor  54 , and outer body panels  56 . Front-end structure  50  is mounted to body structure  24  and may be mounted according to various methods. In the present example, front-end structure  50  is mounted on first mounting surfaces provided by body structure  24  via bolted connections (not shown). The mounting surfaces are provided at four locations identified by reference numerals  60   a - d  ( FIG. 2 ). 
         [0050]    Front suspension  52  includes two front wheels  62 . Electric motor  54  is mounted to front-end structure  50  and is part of a drivetrain that drives the front wheels  62 . An energy storage system including a rechargeable battery  64  provides energy to electric motor  54 . Battery  64  is mounted to an underside of body structure  24  as described in further detail below. Outer body panels  56  are mounted to front-end structure  50  and cover portions of front-end module  20 . Outer body panels  56  include a hood  66  providing selective access to components housed within front-end module  20 , such as electric motor  54 . 
         [0051]    Rear-end module  22  is separate from front-end module  20  and includes a rear-end structure  70 , a rear suspension  72 , and outer body panels  74 . Rear-end structure  70  is mounted to body structure  24  and may be mounted according to various methods. In the present example, rear-end structure  70  is mounted on second mounting surfaces provided by body structure  24  via bolted connections (not shown). The second mounting surfaces are provided at three locations identified by reference numerals  76   a - c  ( FIG. 4 ). Rear suspension  72  includes a rear wheel  78 . Outer body panels  74  are mounted to rear-end structure  70  and cover portions of rear-end module  22 . Outer body panels  74  include an access panel  80  providing selective access to components housed within rear-end module  22 , such as rear wheel  78 . 
         [0052]    Doors  30 ,  32  and hatch  34  are mounted to body structure  24  within door openings  82 ,  84  and rear hatch opening  86 , respectively, via bolted connections (not shown). Doors  30 ,  32  are mounted on third and fourth mounting surfaces, respectively, and hatch  34  is mounted on fifth mounting surfaces. The third, fourth, and fifth mounting surfaces are provided by the body structure  24 . The third mounting surfaces are provided at two locations identified by reference numerals  88   a - b  ( FIG. 6 ). The fourth mounting surfaces are provided at two locations identified by reference numerals  90   a - b  ( FIG. 2 ). The fifth mounting surfaces are provided at two locations identified by reference numerals  92   a - b  ( FIG. 3 ). Windshield  36  is mounted to body structure  24  within a windshield opening  94 . Rear side glass  38 ,  40  is mounted to body structure  24  within side openings  96 ,  98 , respectively. 
         [0053]    With additional reference to  FIGS. 2-7 , body structure  24  includes a monocoque construction  100  that provides a primary structure that supports vehicle  10 . In particular, body structure  24  carries loads generated by passengers and other cargo within the passenger compartment  44 . Composite body structure  24  also connects front suspension  52  and rear suspension  72  and carries suspensions loads generated by vehicle  10 . Composite body structure  24  further supports various body closures, such as doors  30 ,  32 , rear hatch  34 , windshield  36 , and rear side glass  38 ,  40  and carries loads transmitted by the body closures. 
         [0054]    Generally, monocoque construction  100  includes various composite panels joined by a structural adhesive. Various structural adhesives may be used. In the present example, the adhesive is a two-part methacrylate adhesive. The composite panels include contoured outer panels defining portions of an exterior of vehicle  10  and contoured inner panels defining portions of passenger compartment  44 . The inner and outer panels typically include flanges where the panels join. The outer panels provide mounting surfaces and attachment points for various exterior components, such as the body closures. The inner panels provide mounting surfaces and attachment points for various interior components of vehicle  10 , such as seats (not shown), an instrument panel (not shown), and interior trim (not shown). A construction and a thickness of the composite panels varies to provide a desired surface finish and desired structural characteristics, such as a desired strength. Exemplary constructions and thicknesses are illustrated in the drawings and discussed in further detail below. 
         [0055]    Monocoque construction  100  includes a floor pan  110 , an inner reinforcement frame structure or spider  112 , a first outer panel  114 , a second outer panel  116 , a first closeout panel  118 , a second closeout panel  120 , and a cowl panel  122 . Floor pan  110  extends along a longitudinal axis  130  and includes a lower surface  132  generally facing an underside of vehicle  10  and an upper surface  134  opposite lower surface  132  generally facing upward and toward an interior of vehicle  10 . 
         [0056]    Floor pan  110  includes a floor  140 , a front wall  142 , side walls  144 ,  146 , and a rear wall  148 . Floor  140  is a single piece part (i.e., unitary) including raised sections including a first section  150 , a second section  152 , tunnel sections  154 ,  156 , and seat rail sections  158 ,  160 ,  162 ,  164 . First section  150  is a multi-sided construction defining a suspension well  170 . First section  150  includes a front wall  172  and a top wall  174  on two sides providing the mounting surfaces for the rear suspension  72 . Second section  152  is a multi-sided construction defining a battery well  180 . Second section  152  includes a front wall  182 , a ridge  184 , and a top wall  186 . Ridge  184  extends between front wall  182  and top wall  186  in a longitudinal direction and between sides of second section  152 . 
         [0057]    Tunnel sections  154 ,  156  define a longitudinally extending tunnel  190 . Tunnel section  154  longitudinally extends between and connects front wall  142  and front wall  182 . With additional reference to  FIG. 26 , Tunnel section  154  includes side walls  192  and a top wall  194 . Tunnel section  156  longitudinally extends between and connects first section  150  and second section  152 . Tunnel section  156  includes side walls  196  extending from a top wall  198 . 
         [0058]    Seat rail sections  158 ,  160  longitudinally extend between and connect side wall  144  and tunnel section  154 . Seat rail sections  162 ,  164  longitudinally extend between and connect side wall  146  and tunnel section  154 . Seat rail sections  158 ,  160  can be substantially similar to seat rail sections  162 ,  164 , respectively. For brevity, seat rail sections  158 ,  160  will be described with the understanding that the following description applies equally to seat rail sections  162 ,  164 . Seat rail section  158  is longitudinally spaced apart from seat rail section  160 . With additional reference to  FIG. 29 , seat rail section  158  includes side walls  200  and a top wall  202 . Seat rail section  160  includes side walls  204  and a top wall  206 . Top walls  202 ,  204  and side walls  200  and  204  provide mounting surfaces for a seat (not shown) as indicated by reference numerals  207   a - h  in  FIG. 4 . 
         [0059]    Spider  112  is mounted on floor pan  110  and surrounds a majority of an upper portion of the passenger compartment  44 . Spider  112  is a single piece part including an inner surface  208  generally facing the interior and an outer surface  209  opposite inner surface  208  generally facing the exterior. Spider  112  further includes a frame  210 , vertically extending support members  212 ,  214 ,  216 ,  218 , and laterally extending support member  220 . Together, frame  210  and support members  212 ,  214 ,  216 ,  218 ,  220  define a roof bond flange  222 , an inner windshield bond flange  224 , and inner body side opening flanges  226 ,  228 . Roof bond flange  222  surround and define part of a roof opening  230 . Inner windshield bond flange  224  surrounds and defines part of windshield opening  94 . Inner body side opening flanges  226 ,  228  surround and define parts of door openings  82 ,  84 , respectively. 
         [0060]    Frame  210  includes header rails  232 ,  234 , and side rails  236 ,  238 . Header rail  232  extends laterally between and connects support members  212 ,  214  and creates part of a front header section as illustrated in  FIG. 19 . Header rail  232  includes a contoured section  240 , a forward flange  242 , a rearward flange  244 . Contoured section  240  extends between flanges  242 ,  244  and has a generally U-shape cross-section. 
         [0061]    Header rail  234  extends laterally between and connects support members  216 ,  218  and creates part of a rear header section as illustrated in  FIG. 20 . Header rail  234  includes a contoured section  246 , a forward flange  248 , and a rear flange  250 . Contoured section  246  extends between flanges  248 ,  250  and has a generally U-shape cross-section. 
         [0062]    Side rail  236  longitudinally extends between and connects support members  212 ,  216  and includes a contoured section  252 , an outer flange  254 , and an inner flange  256 . Side rail  238  longitudinally extends between and connects support members  214 ,  218  and includes a contoured section  258 , an outer flange  260 , and an inner flange  262 . 
         [0063]    Support members  212 ,  214  create parts of corresponding a-pillar sections as illustrated in  FIG. 23  for support member  214 . Support member  212  includes a contoured section  264 , an outer flange  266 , and an inner flange  268 . Support member  214  includes a contoured section  270 , an outer flange  272 , and an inner flange  274 . Contoured section  270  extends between flanges  272 ,  274  and has a generally U-shape cross-section. 
         [0064]    Support members  216 ,  218  create parts of corresponding b-pillar sections as illustrated in  FIGS. 24-25 . Support member  216  includes a contoured section  276 , a forward flange  278 , and a rearward flange  280 . Contoured section  276  extends between flanges  278 ,  280  and has a generally U-shape cross-section. Contoured section  276  includes a vertical wall  282 . Vertical wall  282  is joined to a complementary side wall of second section  152 . 
         [0065]    Support member  218  includes a contoured section  284 , a forward flange  286 , and a rearward flange  288 . Contoured section  284  extends between flanges  286 ,  288  and has a generally U-shape cross-section. Contoured section  282  includes a vertical wall  289 . Vertical wall  289  is joined to a complementary side wall of second section  152 . 
         [0066]    Support member  220  extends laterally between and connects ends of support members  212 ,  214  opposite frame  210  and creates part of a dash/cowl section as illustrated in  FIG. 18 . Support member  220  includes an upper flange  290 , a lower flange  292 , a contoured section  294 , and end caps  296 ,  298 . Contoured section  294  extends between upper and lower flanges  290 ,  292  and end caps  296 ,  298  and generally has a U-shape cross-section. Upper flange  290  is joined to first outer panel  114 . Lower flange  292  is joined to floor pan  110 . End caps  296 ,  298  include vertical walls that are joined to floor pan  110 . End cap  296  is joined to front wall  142  and side wall  144 . End cap  298  is joined to front wall  142  and side wall  146 . 
         [0067]    First outer panel  114  is joined to floor pan  110  and spider  112 . First outer panel  114  is a single piece part including an inner surface  320  and an outer surface  322 . Outer surface  322  includes portions having a Class-A surface. Although first outer panel  114  may be a single part as discussed herein, first outer panel  114  may be segmented into more than one part. For example, first outer part  114  may include a first part including the Class-A surface and a second part including a non-Class-A surface. 
         [0068]    First outer panel  114  further includes an a-pillar part  330 , a roof panel part  332 , a quarter panel part  334 , and a rocker panel part  336 . Together, a-pillar part  330 , roof panel part  332 , quarter panel part  334 , and rocker panel part  336  create contiguous portions of an outer windshield bond flange  338 , an outer door opening flange  339 , a rear hatch sealing flange  340 , and a lower bonding flange  341 . Outer windshield bond flange  338  defines windshield opening  94 . Outer door opening flange  339  defines door opening  82 . Rear hatch sealing flange  340  defines rear hatch opening  86 . Lower bonding flange  341  extends along a lower portion of first outer panel  114  and is used to bond first outer panel  114  to floor pan  110 . 
         [0069]    A-pillar part  330  extends from forward ends of roof panel part  332  and rocker panel part  336  and includes a portion of inner and outer surfaces  320 ,  322 . In alternate implementations, a-pillar part  330  can be a separate part joining roof panel part  332  and rocker panel part  336 . A-pillar part  330  includes a first section  342  at an upper end and a second section  344  at a lower end. First section  342  creates part of an a-pillar section substantially similar to the a-pillar section illustrated in  FIG. 23 . First section  342  includes a contoured section  346  and flanges  348 ,  350  (see  FIG. 12 ). Second section  344  extends from first section  342  and includes adjoining wall sections  352 ,  354 , and a tie rail  356 . Second section  344  further includes the lower mounting surface for door  30  at location  88   b  ( FIG. 6 ). Tie rail  356  extends from wall sections  352 ,  354  and includes a stepped flange  358  at an end opposite wall sections  352 ,  354 . 
         [0070]    Roof panel part  332  extends from a-pillar part  330  to an upper end of quarter panel part  334  and includes a portion of inner and outer surfaces  320 ,  322 . Roof panel part  332  further includes a contoured section  380 , flanges  382 ,  384 ,  386  and tie rails  388 ,  390 . Contoured section  380  extends between flanges  382 ,  384 ,  386  and tie rails  388 ,  390 . Contoured section  380  includes the upper mounting surface for door  30  at location  88   a  ( FIG. 6 ). Flange  382  includes a portion of outer windshield bond flange  338 . Flange  384  includes a portion of outer door opening flange  339 . Flange  386  defines a portion of roof opening  230 . Tie rails  388 ,  390  include stepped flanges  392 ,  394 , respectively, that join to complementary portions of second outer panel  116  and create a contiguous surface between first and second outer panels  114 ,  116 . 
         [0071]    Quarter panel part  334  extends from ends of a-pillar part  330  and rocker panel part  336  to rear wall  148  of floor pan  110  and includes a portion of inner and outer surfaces  320 ,  322 . Quarter panel part  334  further includes a contoured section  400 , flanges  402 ,  404 ,  406 ,  408 , and a tie rail  410 . Contoured section  400  extends between flanges  402 ,  404 ,  406 ,  408 , and tie rail  410 . Contoured section  400  includes an access pocket  412  for receiving a plug (not shown) for charging battery  64 . Flange  402  includes a portion of outer door opening flange  339 . Flange  404  includes a portion of lower bonding flange  341  Flange  406  includes a portion of rear hatch sealing flange  340 . Flange  408  includes a portion of a bonding flange for side glass  38 . Tie rail  410  laterally extends from a rear end of quarter panel part  334  and includes a stepped flange  414  at an inboard end. Stepped flange  414  is joined to complementary portions of second outer panel  116  and creates a contiguous surface between first and second outer panels  114 ,  116 . 
         [0072]    Rocker panel part  336  extends between a-pillar part  330  and quarter panel part  334  and creates a rocker section as illustrated in  FIG. 22 . The rocker section extends rearward to a location adjacent a rear end of second section  152 . Rocker panel part  336  includes a portion of inner and outer surfaces  320 ,  322 . Rocker panel part  336  further includes a contoured section  430  and flanges  432 ,  434 . Contoured section  430  extends between flanges  432 ,  434 . Flange  432  includes a portion of outer door opening flange  339 . Flange  434  includes portions of lower bonding flange  341 . 
         [0073]    Second outer panel  116  is joined to floor pan  110  and spider  112 . Generally, second outer panel  116  is a mirror image of first outer panel  114 . Second outer panel  116  is a single piece part including an inner surface  460  and an outer surface  462 . First outer panel  114  further includes an a-pillar part  470 , a roof panel part  472 , a quarter panel part  474 , and a rocker panel part  476 . Together, a-pillar part  470 , roof panel part  472 , quarter panel part  474 , and rocker panel part  476  create a contiguous second portion of outer windshield bond flange  338  and a contiguous second portion of rear hatch sealing flange  340 . A-pillar part  470 , roof panel part  472 , quarter panel part  474 , and rocker panel part  476  further create an outer door opening flange  480  and a lower bonding flange  482 . Outer door opening flange  480  defines portions of door opening  84 . Lower bonding flange  482  extends along a lower portion of second outer panel  116  and joins a lower portion of second outer panel  114  to floor pan  110 . 
         [0074]    A-pillar part  470 , roof panel part  472 , quarter panel part  474 , and rocker panel part  476  include features substantially similar to the features of a-pillar part  330 , a roof panel part  332 , a quarter panel part  334 , and a rocker panel part  336  discussed above. Accordingly, for brevity, the differences will be discussed. A-pillar part  470  includes a tie rail  490  substantially similar to tie rail  356 , except an end of tie rail  490  is complementary to stepped flange  358 . Similarly, roof panel part  472  includes tie rails  492 ,  494  having ends complementary to stepped flanges  392 ,  394  of tie rails  388 ,  390 , respectively. Quarter panel part  474  includes a tie rail  496  having an end complementary to stepped flange  414  of tie rail  410 . 
         [0075]    First closeout panel  118  is joined to floor pan  110 , spider  112 , and first outer panel  114 . Together, first closeout panel  118 , floor pan  110 , and spider  112  create a b-pillar section substantially similar to the b-pillar section illustrated in  FIG. 25 . The b-pillar section is coupled to the rocker section created by floor pan  110  and first outer panel  114  illustrated in  FIG. 22 . 
         [0076]    First closeout panel  118  includes a contoured section  500 , flanges  502 ,  504 , and a front wall  506 . Contoured section  500  extends between flanges  502 ,  504 , and front wall  506 . Flange  502  is located at an outboard side and is joined to a complementary portion of inner surface  320 . Flange  504  is located at a lower portion and is joined to a complementary adjoining portion of upper surface  134 . Front wall  506  extends vertically and is joined to a complementary adjoining portion of inner surface  208 . 
         [0077]    Second closeout panel  120  is joined to floor pan  110 , spider  112 , and second outer panel  116 . Together, second closeout panel  120 , floor pan  110 , spider  112 , and second outer panel  116  create portions of a b-pillar section substantially similar to the b-pillar section illustrated in  FIG. 25 . The b-pillar section is coupled to a rocker section created by floor pan  110  and second outer panel  116  substantially similar to the rocker section illustrated in  FIG. 22 . 
         [0078]    Second closeout panel  120  includes a contoured section  520 , flanges  522 ,  524 , and a front wall  526 . Contoured section  520  extends between flanges  522 ,  524  and front wall  526 . Flange  522  is located at an outboard side and is joined to inner surface  460 . Flange  524  is located at a lower portion and is joined to a complementary portion of upper surface  134 . 
         [0079]    Cowl panel  122  extends in a longitudinal direction and is joined to spider  112 , first outer panel  114 , and second outer panel  116 , thereby creating a portion of a dash/cowl section as illustrated in  FIG. 18 . Cowl panel  122  includes a contoured section  550  and flanges  552 ,  554 . Contoured section  550  extends between flanges  552 ,  554 . Flange  552  extends along an upper portion and is joined to inner surfaces  320 ,  460 . Flange  554  extends along a lower portion and is joined to support member  220 . 
         [0080]    Referring to  FIGS. 8-17 , a preferred method of joining the various panels during assembly of monocoque construction  100  is illustrated. First, as shown in  FIG. 8 , spider  112  is joined to floor pan  110 , thereby creating an underbody assembly  600 . More specifically, an adhesive  602  joins front and side portions of support member  220  to complementary portions of front wall  142  and side walls  144 ,  146 . an adhesive  604  joins flanges  278 ,  280  to side walls  144  and vertical wall  282  to complementary sidewalls of second section  152 . Although not specifically shown in  FIG. 8 , adhesive joins support  218  to floor pan  110  in a similar manner as adhesive  604 . 
         [0081]    Next, as shown in  FIGS. 9-12 , first outer panel  114  is joined to floor pan  110  and spider  112 . Adhesive  610 ,  612 ,  614  joins forward portions of underbody assembly  600  to complementary portions of a-pillar part  330 . Adhesive  612 ,  614  and adhesive  616 ,  618  joins an upper portion of underbody assembly  200  to roof panel part  332 . Adhesive  614 ,  616  and adhesive  620 ,  622  joins a portion of underbody assembly  600  to quarter panel part  334 . 
         [0082]    Next, second outer panel  116  is joined to floor pan  110 , spider  112 , and first outer panel  114 . Second outer panel  116  is joined to the floor pan  110  and spider  112  using structural adhesive in a substantially similar way as described above for first outer panel  114  and thus will not be described in detail. Referring back to  FIG. 3 , structural adhesive  630 ,  632 ,  634 ,  636  joins tie rails  356 ,  388 ,  390 ,  410  to tie rails  490 ,  492 ,  494 ,  496 , respectively. 
         [0083]    Next, as shown in  FIGS. 13-14 , first closeout panel  118  is joined to floor pan  110 , spider  112 , and first outer panel  114 . An adhesive  650  joins flange  502  to inner surface  320 . An adhesive  652  joins flange  504  to upper surface  134 . An adhesive  654  joins front wall  506  to inner surface  208 . 
         [0084]    Next, as shown in  FIG. 15 , second closeout panel  120  is joined to floor pan  110 , spider  112 , and second outer panel  116 . An adhesive  660  joins flange  522  to inner surface  460 . An adhesive  662  joins flange  524  to upper surface  134 . An adhesive  664  joins front wall  526  to inner surface  208 . 
         [0085]    Next, with reference to  FIGS. 16-17 , cowl panel  122  is joined to spider  112 , first outer panel  114 , and second outer panel  116 . An adhesive  670  joins flange  552  to inner surface  320 . An adhesive  672  joins flange  554  to inner surface  460 . 
         [0086]    The present invention is not limited to a particular method for adhesively joining the composite panels of composite body structure  24 . Referring now to  FIG. 30 , a preferred method for joining two panels of composite body structure  24  will now be described. First, two panels  700 ,  702  to be joined are brought into close proximity using fixtures or tooling  704 . While fixtures  704  hold panels  700 ,  702  in place, a through hole  706  is drilled in one of panels  700 ,  702  in an area where adhesive is to be used. Hole  706  may be drilled by hand using a drill fixture (not shown) or, alternatively, by automated methods. It is also contemplated that hole  706  may be preformed in one of panels  700 ,  702 . A head of an adhesive dispenser  708  is inserted in hole  706  and a desired amount of adhesive  710  is pumped into a gap between panels  700 ,  702 . Once the desired amount is delivered, adhesive dispenser  708  may be removed from panel  702  and adhesive  710  is cured. Depending on the location of adhesive, it may be desired to remove a portion  720  of panels  700 ,  702  and adhesive  710  to provide a finished surface  722 . 
         [0087]    Referring to  FIGS. 26-27 , cross-sectional views taken along lines  26 - 26 ,  27 - 27  of  FIG. 3  illustrate additional a-pillar sections showing a cross-car beam  750  mounted to composite body structure  24  via connections  752 . Cross-car beam  750  serves as a support for an instrument panel (not shown) and provides additional lateral structure for resisting a side impact. Cross-car beam  750  can be composed of various materials. For example, cross-car beam can be composed of various metals, such as steel and aluminum. Alternately, or additionally, cross-car beam  750  can be composed of a composite material. Cross-car beam  750  includes a tubular structure  760  extending between and connected to end plates  762 . Connections  752  are bolted connections in which portions of floor pan  110 , spider  112 , and first and second outer panels  114 ,  116  are held between end plates  762  and hinges  770  supporting doors  30 ,  32 . For example, on the right side of vehicle  10 , portions of floor pan  110 , spider  112 , and second outer panel  116  are held between one of end plates  762  as shown. Bolts  772  secure the connection. 
         [0088]    Referring now to  FIG. 31 , an automotive vehicle composite panel  800  is shown as a multi-layer structure including varying arrangements of a core layer  802  and reinforcement layers  804 . During manufacture, reinforcement layers  804  are stacked around core layer  802  and then vacuum impregnated with a resin  806 , so as to provide a composite structure having enhanced structural properties. A first structural region  810  of composite panel  800  includes core layer  802  sandwiched between reinforcement layers  804  with resin  806  interspersed therebetween. This arrangement mechanically secures core layer  802  to reinforcement layers  804 , while still providing resin  806  as a high gloss, Class-A finish on an outer surface  812 . 
         [0089]    A second structural region or flange  814  is contiguous with first structural region  810  and is located around the perimeter of composite panel  800 . Flange  814  includes only reinforcement layers  804  impregnated with resin  806 . Removal of core layer  802  provides flange  814  with a reduced weight and thickness as compared to first structural region  810 . The arrangement of flange  814  provides a finished end to composite panel  800 , but also provides a region for securement to other materials and components, such as, secondary composite panels, metallic flanges, etc. These additional components can be secured to flange  814  by securing an attachment mechanism therewith. 
         [0090]    Various laminar structures can be used with composite panel  800 . For example,  FIG. 32  illustrates a laminar structure  820 , typically used for flange  814 . Laminar structure  820  includes multiple layers of carbon-free fiber material  822 . Laminar structure  820  may optionally include a veil sheet  824  and/or a paint layer  826 . If used, veil sheet  824  is located immediately adjacent carbon-free fiber material  822  and within cured resin material. Accordingly, veil sheet  824  is disposed between paint layer  826  and corresponding carbon-free fiber material  822 . Veil sheet  824  assists in preventing print-through of carbon-free fiber material  822 , while still offering abrasion and impact resistance. Paint layer  826  is adhered to outer surface  812  of composite panel  800  for providing a high gloss, Class-A surface on composite panel  800 , thereby allowing composite panel  800  to be used as an exterior surface. As should be understood, veil sheet  824  and/or paint layer  826  are only provided as an optional configuration. 
         [0091]    Referring now to  FIG. 33 , certain elements may be secured to composite panel  800  during vehicle assembly. For example, a second composite panel  830  may be secured to composite pane!  800  with a fastener arrangement  832 . Fastener arrangement  832  may include a bolt  834  and a washer or hardware  836  in contact with composite panel  800  at a reduced thickness laminar region. A nut  840  and a washer or hardware  842  may be secured to bolt  834  so as to be in contact with second composite panel  830 . While securement of similarly designed composite panels  800 ,  830  is described, it should be understood that various other components may also be secured to composite panel  800  with fastener arrangement  832  in substantially the same manner. 
         [0092]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention.