Patent Publication Number: US-7591502-B2

Title: Tunable inner fender structure

Description:
BACKGROUND OF THE INVENTION 
   Field of the Invention 
   The present invention relates to a tunable inner fender structure. 
   SUMMARY OF THE INVENTION 
   In at least one embodiment of the present invention, a tunable inner fender structure is provided. The tunable inner fender structure includes a body having a set of apertures and a tunable member. The tunable member extends through the set of apertures and has a preweakened area. The tunable member and the body cooperate to absorb energy when sufficient force is applied to distort the tunable member. 
   In at least one other embodiment of the present invention, a tunable inner fender structure is provided. The tunable inner fender structure includes a casting and a tunable member. The casting includes a mounting portion and an arm portion extending from the mounting portion. The arm portion has a set of apertures that are spaced apart from each other. The tunable member extends through the set of apertures. Folding of the arm portion is inhibited by the tunable member when the tunable member is not deformed. 
   In at least one other embodiment of the present invention, a tunable inner fender structure for a vehicle is provided. The tunable inner fender structure includes an arm portion and a tunable member. The arm portion has a set of web panels. Each web panel includes an aperture and intersects at least one other member of the set of web panels. The tunable member extends through the apertures to control folding of the arm portion during a vehicle impact event. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a partially exploded perspective view of an exemplary vehicle having a vehicle body assembly. 
       FIG. 2  is a partially exploded perspective view of the vehicle body assembly of  FIG. 1  having a vehicle body structure. 
       FIG. 3  is an exploded perspective view of a portion of the vehicle body structure shown in  FIG. 2 . 
       FIG. 4  is an exploded perspective view of a first zone of the vehicle. 
       FIG. 5  is a top section view of an embodiment of the inner fender structure shown in  FIG. 4  along section line  5 - 5 . 
       FIG. 6  is a top section view of the inner fender structure of  FIG. 5  in an exemplary deformed condition. 
       FIG. 7  is a perspective view of another embodiment of an inner fender structure. 
       FIG. 8  is a top section view of the inner fender structure of  FIG. 7  along section line  8 - 8 . 
       FIG. 9  is a top section view of the inner fender structure of  FIG. 8  in an exemplary deformed condition. 
       FIG. 10  is a perspective view of a first embodiment of an engine support structure. 
       FIG. 11  is a side view of an engine support structure disposed in the vehicle. 
       FIG. 12  is a perspective view of a second embodiment of an engine support structure. 
       FIG. 13  is an exploded perspective view of a second zone of the vehicle. 
       FIG. 14  is a fragmentary perspective view of a portion of a closure frame structure. 
       FIG. 15  is an exploded fragmentary perspective view of an interface between an inner fender structure and a closure frame structure. 
       FIG. 16  is a fragmentary view of an embodiment of a closure hinge. 
       FIG. 17  is an exploded perspective view of another embodiment of a closure hinge. 
       FIG. 18  is a section view of a portion of the closure hinge shown in  FIG. 17 . 
       FIGS. 19-22  are exploded perspective views of various embodiments of a third zone of the vehicle. 
       FIGS. 23-26  are exploded perspective views of various embodiments of a fourth zone of the vehicle. 
       FIG. 27  is an exploded perspective view of a floor structure. 
       FIG. 28  is an exploded perspective view of a portion of the floor structure shown in  FIG. 27 . 
       FIGS. 29-36  are various embodiments of mating features that may be provided with vehicle body structure components. 
       FIGS. 37A-37D  are side views of various vehicle configurations. 
       FIGS. 38 and 39  are perspective views of exemplary body panels. 
       FIGS. 40 and 41  are fragmentary perspective views of hinge cover portions of a body panel. 
       FIGS. 42-46  are exemplary embodiments of connections between body panels and the vehicle body structure. 
   

   DETAILED DESCRIPTION 
   Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention. 
   Referring to  FIGS. 1 and 2 , an exemplary vehicle  10  is shown. The vehicle  10  may be of any suitable type, such as a motor vehicle like an automobile. For clarity, the vehicle  10  is shown without select components, such as wheels, tires, and drivetrain components. 
   The vehicle  10  may include a vehicle body assembly  12  having a vehicle body structure  14  and a plurality of body panels  16 . For illustration purposes, at least a portion of the body panels  16  are fragmented or removed in  FIG. 2  to better show the vehicle body structure  14 . 
   The vehicle body assembly  12  and vehicle body structure  14  may include an upper portion  18  and a lower portion  20 . The upper portion  18  may define at least a portion of an engine compartment  22  and at least a portion of a passenger compartment  24 . In the embodiment shown, the engine compartment  22  is disposed proximate the front of the vehicle  10 ; however, the engine compartment  22  may be disposed in any suitable location, such as toward the rear of the vehicle  10 . The body panels  16  may be disposed on the upper portion  18  as will be described in more detail below. In addition, one or more closures, such as a door, hood, liftgate, tailgate, trunk lid, hatchback, or the like, may be moveably disposed on the upper portion  18 . 
   The lower portion  20  may generally be disposed under the upper portion  18  and may also define at least a portion of the engine compartment  22  and/or the passenger compartment  24 . The lower portion  20  may at least partially define a floor assembly in one or more embodiments of the present invention as will be discussed in more detail below. 
   Referring to  FIG. 3 , an exploded view of the vehicle body structure  14  is shown. For clarity, closure structures associated with the passenger compartment  24  are not shown to better illustrate other components of the vehicle body structure  14 . 
   The vehicle body structure  14  may be made up of a set of components. A member of the set of body structure components may interlock with at least one another member of the set when the vehicle body structure  14  is assembled. The interlocking members of the set may have different configurations and may include one or more types of mating features as will be described in more detail below. 
   In at least one embodiment, at least some of the members of the set of body structure components may be provided as castings and may be provided with integral mating features. For example, the integral mating features may be cast as part of an associated body structure component, thereby providing a one-piece construction. In addition, members of the set of body structure components may be made of any suitable material. For example, at least some of the members of the set of body structure components may be made of a magnesium alloy to provide desirable strength, weight, and manufacturability characteristics. 
   The vehicle  10 , vehicle body assembly  12 , and/or vehicle body structure  14  may include a plurality of zones. Each zone may include a subset of the set of body structure components and may include one or more components that are part of the upper and lower portions  18 , 20 . For example, the vehicle body structure  14  may include a first zone  30  disposed proximate a front end of the vehicle  10 , a second zone  32  that may be disposed adjacent to the first zone  30 , a third zone  34  that may be disposed adjacent to the second zone  32 , and a fourth zone  36  that may be disposed adjacent to the third zone  34  and proximate a rear end of the vehicle  10 . 
   Referring to  FIG. 4 , an exploded view of an exemplary first zone  30  of the vehicle  10  is shown. For clarity, the first zone  30  is shown without body panels to more clearly depict the underlying portion of the vehicle body structure  14 . The first zone  30  may at least partially define the engine compartment  22  of the vehicle  10  and may include a hood closure structure  100 , a front end structure  102 , a first inner fender structure  104 , a second inner fender structure  106 , and an engine support structure  108 . 
   The hood closure structure  100  may be pivotally attached to another vehicle body structure component to cover or provide access to the engine compartment  22 . The hood closure structure  100  may include a plurality of ribs  110  that provide structural reinforcement and a plurality of openings  112  to reduce weight and material usage. In at least one embodiment, the hood closure structure  100  may be a casting. In addition, one or more body panels may be disposed proximate the hood closure structure  100  to at least partially conceal the hood closure structure  100  and provide an exterior vehicle surface. 
   The front end structure  102  may be provided proximate the front end of the vehicle  10 . In at least one embodiment, the front end structure  102  may extend across the front end of the vehicle  10  and may include one or more airflow openings  114  that permit airflow toward the engine compartment  22 . In addition, the front end structure  102  may include openings for receiving other vehicle components, such as lights or latches, and may receive a front end bumper structure and/or body panel. 
   The front end structure  102  may include mating features for engaging another vehicle body structure component. For example, as is best shown in  FIG. 3  the front end structure  102  may include first and second front end mating features  116 , 118  that engage or interlock with the first and second inner fender structures  104 , 106 , respectively. In one or more embodiments of the present invention, one or more fasteners may be used to couple the front end structure  102  to the first and second inner fender structures  104 , 106 . 
   The first and second inner fender structures  104 , 106  may be configured to absorb energy during a vehicle impact event to help protect a vehicle occupant. For instance, the inner fender structures  104 , 106  may be configured to distort (e.g., fold, buckle, collapse, or otherwise change shape) when sufficient force is transmitted to an inner fender structure. 
   The first and second inner fender structures  104 , 106  may be spaced apart from each other and disposed along opposite sides of the vehicle  10 . In the embodiment shown in  FIG. 4 , the first and second inner fender structures  104 , 106  are generally configured as mirror images of each other. For simplicity, only the first inner fender structure  104  will be described in detail below with the understanding that the second inner fender structure  106  may have similar attributes. 
   The inner fender structure  104  may include a body  120  having a mounting portion  122  and an arm portion  124  that extends from the mounting portion  122 . The body  120  may be provided such that the mounting and arm portions  122 , 124  are integrally formed as a one-piece component. 
   The mounting portion  122  may be adapted to mount to another vehicle body structure component as will be described in more detail below. In at least one embodiment, the mounting portion  122  may include a mating feature  126  configured as a mortise. 
   The arm portion  124  may extend from the mounting portion  122  toward the front of the vehicle  10 . The arm portion  122  may have a distal end  128  spaced apart from the mounting portion  122 . The distal end  128  may engage or interlock with the front end structure  102 . In addition, one or more mating features  130  may be associated with the distal end  128 . The distal end  128  and/or the mating features  130  may have a male configuration, female configuration, or combinations thereof. The arm portion may be disposed toward an upper surface of the vehicle  10  to help counter “vaulting” or lifting of the rear wheels from the ground and to help occupants remain in a location where one or more occupant protection devices may be effective during a vehicle impact event. 
   Referring to  FIGS. 4 and 5 , one embodiment of an arm portion  124  is shown in more detail. The arm portion  124  may include a plurality of pockets  132 . Each pocket  132  may include at least one opening  134 . The openings  134  of adjacent pockets may be disposed along opposite sides of the arm portion  124 . As such, the arm portion  124  may be configured to distort in a preconfigured manner when sufficient force is transmitted to the arm portion  124 . In addition, at least one reinforcement feature  136  may partially fill one or more pockets  132  to help maintain a pocket configuration under ordinary conditions. 
   Referring to  FIG. 5 , a cross section of the arm portion  124  of the inner fender structure  104  is shown. The inner fender structure  104  and/or arm portion  124  may include one or more walls that help define one or more pockets  132 . For example, the inner fender structure  104  may include a serpentine wall  140  that at least partially defines one or more pockets  132 . As such, one or more portions of the serpentine wall  140  may separate adjacent pockets  132 . The pockets  132  may have any suitable configuration. In at least one embodiment, the pockets  132  may increase in size in a direction extending from the distal end  128  toward the mounting portion  122 . Moreover, at least a portion of the serpentine wall  140  may be stronger than one or more other walls to help direct or respond to load forces in a desired manner. 
   A back wall  142  may be disposed opposite one or more openings  134 . In the embodiment shown in  FIG. 5 , the back wall  142  is provided as part of the serpentine wall  140 . 
   First and second longitudinal walls  144 , 146  may also at least partially define one or more pockets  132 . In at least one embodiment, the first and second longitudinal walls  144 , 146  may be spaced apart from each other and extend from the mounting portion  122 . In addition, the first and second longitudinal walls  144 , 146  may be disposed proximate the serpentine wall  140  and/or back wall  142 . 
   One or more pre-weakened areas  148  may be provided that influence the load bearing characteristics of the arm portion  124 . A pre-weakened area  148  may be provided that at least partially extends through one or more walls. For instance, a plurality of pre-weakened areas  148  may be provided in the first and second longitudinal walls  144 , 146  proximate the serpentine wall  140  and/or an opening  134 . 
   At least some of the walls  140 , 142 , 144 , 146  and pockets  132  may distort when sufficient force is applied. Moreover, the walls  140 , 142 , 144 , 146  and pockets  132  may be configured to withstand different load forces or absorb different amounts of energy. For example, one or more walls and/or pockets may be distorted or change shape under lower load forces than other walls, portions of walls, and/or pockets. In at least one embodiment, the arm portion  124  may be configured to withstand higher load forces closer to the mounting portion  122  than the distal end  128 . Moreover, the arm portion  124  may generally be configured to deform prior to deformation of the mounting portion  122 . 
   Referring to  FIG. 6 , the arm portion  124  of the inner fender structure  104  is shown in an exemplary deformed condition. Deformation may result in a reduction in length of the arm portion  124  due to reduced size or volume of one or more pockets  132 . The arm portion  124  may be configured to deform in a predetermined manner. For instance, one or more walls may deform such that a pocket  132  collapses or folds in a predetermined direction. In  FIG. 6 , a plurality of partially collapsed pockets  132  is shown such that the serpentine wall  140  and partially collapsed pockets are partially folded toward an associated opening  132 . 
   Referring to  FIGS. 7 and 8 , another embodiment of an inner fender structure  150  is shown. The inner fender structure  150  may include a body  152  having a mounting portion  154  and an arm portion  156  that extends from the mounting portion  154 . The body  152  may be provided such that the mounting and arm portions  154 , 156  are integrally formed as a one-piece component. The inner fender structure  150  may also include a tunable member  158 , a first end plate  160 , and a second end plate  162 . 
   The mounting portion  154  may be adapted to mount to another vehicle body structure component as will be described in more detail below. The mounting portion  154  may have a similar configuration as described above with respect to inner fender structure  104 . 
   The arm portion  156  may include a first panel  164 , a second panel  166 , and a set of web panels  168 . The first and second panels  164 , 166  may extend from the mounting portion  154  and may be generally symmetrical and spaced apart from each other. The first and second panels  164 , 166  may have a configuration that helps the arm portion  156  distort in a predetermined manner as will be described in more detail below. 
   The web panels  168  may extend between the first and second panels  164 , 166 . In the embodiment shown, the web panels  168  are disposed in a corrugated arrangement such that adjacent web panels  168  are disposed at an angle relative to each other. Each web panel  168  may intersect or be spaced apart from another web panel. In addition, one or more web panels  168  may be disposed generally perpendicular to at least one of the first and second panels  164 , 166 . 
   One or more of the web panels  168  may include an aperture  170 . The apertures  170  may be arranged along an axis  172 . 
   The tunable member  158  may affect the energy absorption characteristics of the inner fender structure  150 . The tunable member  158  may have any suitable configuration. In the embodiment shown, the tunable member  158  is configured as a tubular channel. The tunable member  158  may extend through the apertures  170  and may be made of any suitable material, such as a metal like steel. A separator, such as a coating or spacer, may be provided between the tunable member  158  and one or more apertures  170  to inhibit galvanic corrosion in one or more embodiments of the present invention. 
   The tunable member  158  may include one or more pre-weakened areas  174 . The pre-weakened areas  174  may be provided in any suitable manner. For example, the pre-weakened areas  174  may be provided as a plurality of indentations or holes that may be spaced apart from each other and may extend at least partially through the tunable member  158 . For example, the pre-weakened areas  174  may be spaced apart from each other in one or more directions, such as in a direction extending along axis  172 . The pre-weakened areas  174  may “tune” or configure the tunable member  158  to distort in a predetermined manner when sufficient force is applied as will be discussed in more detail below. As such, different tunable members may be employed to provide different response characteristics for application in different vehicle packages. In addition, the tunable member  158  may be configured such that different areas deform at different load thresholds. 
   The first and second end plates  160 , 162  may be adapted to constrain the tunable member  158 . The first end plate  160  may be disposed proximate a distal end of the arm portion  156  and proximate a first end of the tunable member  158 . The second end plate  162  may be provided at a second end of the tunable member  158  disposed opposite the first end. The first and second end plates  160 , 162  may be made of any suitable material, such as a metal like steel, and may be adapted to withstand load forces associated with a vehicle impact event. In addition, the first and second end plates  160 , 162  may be coupled to the inner fender structure  150  in any suitable manner, such as with one or more fasteners or by insertion into an opening. For instance, the second end plate  162  may be received in an opening or pocket disposed proximate the mounting portion  154  as shown with hidden lines in  FIG. 7 . 
   Referring to  FIG. 9 , an inner fender structure  150  is shown in an exemplary deformed condition. Deformation of the arm portion  156  may be facilitated when the tunable member  158  is deformed and may be inhibited when the tunable member  158  is not deformed. As such, the arm portion  156  and tunable member  158  may cooperate to absorb energy. Deformation of the tunable member  158  may be affected by its strength characteristics. For example, the tunable member  158  may have lower distortion resistance proximate a pre-weakened area  174 . 
   The arm portion  156  may be configured to deform in a predetermined manner. For example, the first and second panels  164 , 166  and web panels  168  may cooperate with the tunable member  158  to fold back and forth when sufficient force is applied. As such, one or more web panels  168  may be configured to distort or fold relative to another web panel when an associated area of the tunable member  156  is deformed. 
   Referring to  FIG. 10 , one embodiment of an engine support structure  108  is shown. The engine support structure  108  may include a first frame rail  180 , a second frame rail  182 , and a cradle  184 . 
   The first and second frame rails  180 , 182  may extend from at least one vehicle body structure component. In at least one embodiment, the first and second frame rails  180 , 182  may be spaced apart and extend generally parallel to each other. In addition, the first and second frame rails  180 , 182  may at least partially define a tunnel or passage  186  into which various components, such as a transmission, drive shaft, or conduits may extend. 
   The first and second frame rails  180 , 182  may have similar configurations. For instance, the first and second frame rails  180 , 182  may have the same configuration or may be configured as mirror images of each other. For brevity, the first frame rail  180  will be described in detail below with the understanding that the second frame rail  182  may have similar attributes. 
   The first frame rail  180  may have a first end portion  190  and a second end portion  192  disposed opposite the first end portion. The first end portion  190  may be mounted to a portion of the vehicle body structure in any suitable manner, such as with interlocking mating features and/or fasteners. In addition, the first end portion  190  may include a plurality of branches, such as first and second branches  194 , 196 . The first and second branches  194 , 196  may be spaced apart and may help reinforce a portion of the vehicle body structure. For instance, at least one of the first and second branches  194 , 196  may extend between multiple zones as shown in  FIG. 3  in one or more embodiments of the present invention. 
   The second end portion  192  may extend into the engine compartment  22 . The second end portion  192  may engage another vehicle body structure component, such as the front end structure  102  as represented in  FIG. 2 , or may be spaced apart from the front end structure  102  in a cantilever arrangement as is represented in  FIG. 4 . 
   The cradle  184  may be disposed on the first and second frame rails  180 , 182 . In the embodiment shown in  FIG. 10 , the cradle  184  includes first and second sets of apertures  200 , 202  disposed proximate opposite sides of the cradle  184  that receive the first and second frame rails  180 , 182 , respectively. The members of the sets of apertures may have any suitable configuration, such as holes or open sided slots as is shown in  FIG. 10 . 
   The cradle  184  may also include first and second side portions  204 , 206  that generally extend above and/or between the members of the first and second sets of apertures  200 , 202 , respectively. A bridge  208  may extend between the first and second side portions  204 , 206 . The bridge  208  and/or first and second side portions  204 , 206  may cooperate to support an engine  210 , as shown in phantom in  FIG. 11 . In addition, the first and second side portions  204 , 206  may be attached to opposing first and second inner fender structures to provide additional structural support. In addition, the cradle  184  may be configured to receive or support a steering system component  212 , such as a shaft or steering gear. Like other vehicle body structure components, the cradle  184  may be provided as a one piece casting. In the embodiment shown, the steering system component is generally disposed toward the front of the cradle; however, invention also contemplates that a steering system component may be disposed in any suitable location such as toward the rear side of the cradle. 
   Referring to  FIG. 12 , another embodiment of an engine support structure  220  is shown. The engine support structure may include first and second frame rails  222 , 224  and a cradle  226 . 
   The first and second frame rails  222 , 224  may include a plurality of exterior surfaces  228  and a plurality of pre-weakened areas  230 . The pre-weakened areas  230  may be provided in any suitable manner. For example, the pre-weakened areas  230  may be provided as a plurality of indentations or holes that may be spaced apart from each other and may extend at least partially through the frame rails  222 , 224 . For example, the pre-weakened areas  230  may be spaced between the ends of each frame rail  222 , 224 . The pre-weakened areas  230  may configure the frame rails  222 , 224  to distort in a predetermined manner when sufficient force is applied as will be discussed in more detail below. In addition, the frame rails  222 , 224  may be configured such that different areas deform at different load thresholds. 
   The cradle  226  may have similar features as the cradle  184  shown in  FIG. 10 . In the embodiment shown in  FIG. 12 , the cradle  226  has apertures  232  configured as through holes. In addition, one or more surfaces of the aperture  232  may mate with a frame rail to help position the cradle  226 . 
   The engine support structures  108 , 220  described above may help protect a vehicle occupant during a vehicle impact event. The frame rails may distort between the cradle and frame rail end portions to absorb impact energy. In addition, the frame rails  222 , 224  may have increasing resistance to deformation and/or axial strength in the direction extending from the second end toward the first end to provide desired deformation characteristics. In at least one embodiment, the frame rails may distort between the cradle apertures in an area generally underneath an engine, thereby providing increased area or distance for absorbing energy. 
   Referring to  FIGS. 13 and 14  an exemplary second zone  32  is shown. For clarity, the second zone  32  is shown without body panels to more clearly depict the underlying portion of the vehicle body structure  14 . The second zone  32  may at least partially define a passenger compartment  24  of the vehicle  10 , such as a front portion disposed proximate the first zone  30 . The second zone  32  may include a roof structure  250 , a cowl structure  252 , a first floor structure  254 , a first closure frame structure  256 , a second closure frame structure  258 , a first closure structure  260 , and a second closure structure  262 . 
   The roof structure  250  may at least partially define a roof of the vehicle  10 . For example, the roof structure  250  may extend between the first and second closure structures  256 , 258 . The roof structure  250  may receive one or more body panels and may include a sunroof or moonroof opening in one or more embodiments of the present invention. 
   The roof structure  250  may include a plurality of mating features that engage or interlock with another vehicle body structure component. For instance, the roof structure  250  may include first and second sets of roof mating features  270 , 272  that engage or interlock with the first and second closure structures  256 , 258 , respectively. The first and second sets of roof mating features  270 , 272  may be disposed on a surface of the roof structure  250  that faces the passenger compartment  24 . The roof structure  250  may also include a third set of roof mating features  274  that engage or interlock with a vehicle body structure component disposed in an adjacent zone, such as the third zone  34 . In at least one embodiment, the third set of roof mating features  274  may be disposed along a rear surface of the roof structure  250 . The mating features  270 , 272 , 274  may have any suitable configuration as will be discussed in more detail below. 
   The cowl structure  252  may at least partially separate the engine compartment  22  from the passenger compartment  24 . The cowl structure  252  may be disposed between the first and second closure frame structures  256 , 258  and may be configured to receive an instrument panel and carry structural loads. 
   The cowl structure  252  may include various mating features that engage or interlock with another vehicle body structure component. In at least one embodiment, the cowl structure  252  may include first and second end mating features  280 , 282  that engage or interlock with the first and second closure frame structures  256 , 258 , respectively. The cowl structure  252  may also include mating features that engage or interlock with the first floor structure  254 . For instance, the cowl structure  252  may include a mating region  284  that engages the first floor structure  254 . The mating region  284  may have any suitable configuration and may overlap or include male and/or female features, like a tongue and groove arrangement, to inhibit leakage of fluids or gases. The cowl structure  252  may include elongated portions that extend downwardly to engage the first floor structure  254 . The elongated portions may be generally disposed in front of left and right occupant seating positions and may be generally symmetrical to accommodate left and right hand drive configurations in which the driver is positioned in left or right side seating positions, respectively. 
   The first floor structure  254  may at least partially define a floor of the passenger compartment  24 . The first floor structure  254  may be disposed proximate or may be mounted to the first and second closure structures  256 , 258  and the cowl structure  252 . Additional features of the first floor structure  254  and other lower portion  20  components will be discussed in more detail below. 
   The first and second closure frame structures  256 , 258  may be disposed on opposite sides of the vehicle  10 . Each closure frame structure  256 , 258  may at least partially define an opening that receives a closure structure. In the embodiment shown, the first and second closure frame structures  256 , 258  each extend around and define openings that may receive a closure structure. 
   The first and second closure frame structures  256 , 258  may include various features for mating with other vehicle body structure components. For example, the first and second closure frame structures  256 , 258  may each include an upper mating feature  290 , a structure mating feature  292 , a cowl mating feature  294 , an inner fender mating feature  296 , and a hinge portion  298 . These mating features may be integrally formed with their respective closure frame structures. 
   The upper mating features  290  of the first and second closure frame structures  256 , 258  may engage or interlock with the first and second roof mating features  270 , 272 , respectively. The upper mating features  290  may have any suitable configuration that is compatible with the first and second roof mating features  270 , 272 . 
   At least one structure mating feature  292  may be provided that engages or interlocks with a vehicle body structure component disposed in an adjacent zone, such as the third zone  34 . In at least one embodiment, the structure mating features  292  may be disposed along a rear surface of the closure frame structures  256 , 258  and may have any suitable configuration as will be discussed in more detail below. 
   The cowl mating features  294  of the first and second closure frame structures  256 , 258  may engage or interlock with the first and second end mating features  280 , 282 , respectively. Each cowl mating feature  294  may be disposed on a side of a closure frame structure that is disposed between the inner fender mating feature  296  and hinge portion  298 . The cowl mating features  294  may also receive a portion of an instrument panel in one or more embodiments of the present invention. 
   Referring to  FIGS. 13 and 14 , the inner fender mating features  296  may extend from and be integrally formed with the closure frame structures  256 , 258 . In at least one embodiment, an inner fender mating feature  296  may be disposed along a front surface  300  between an A pillar  302  and a bottom surface  304  of each closure frame structure  256 , 258 . The inner fender mating features  296  may be configured as a tenon that may have a generally rectangular configuration and may extend across the front surface  300  to distribute load forces. At least one sleeve  306  may be provided for receiving a fastener. In addition, a reinforcing rib  308  may extend between one or more sleeves  306  to provide increased strength and distribute load forces. Optionally, the A pillar  302  may be provided with one or more through holes or openings  312  that provide visibility for a vehicle occupant by reducing visual obstructions. 
   Referring to  FIG. 15 , an exemplary connection between a closure frame structure and an inner fender structure is shown. Such a connection may be made without welding the closure frame structure to the inner fender structure. In the embodiment shown, a mating feature  126  configured as a mortise is provided with an inner fender structure and is configured to receive an inner fender mating feature  296  configured as a tenon. Such a configuration may provide a stable mounting configuration and may withstand high load forces, such as may be associated with a vehicle impact event. One or more fasteners may extend at least partially through the mating features  126 , 296  to further couple the inner fender structure and closure frame structure. 
   Other surfaces of the inner fender structure and closure frame structure may cooperate to help distribute load forces. For instance, the front surface  300  of the closure frame structure and back surface  310  of the inner fender structure may be disposed adjacent to each other and transfer load forces from the inner fender structure to the closure frame structure. Moreover, the front and back surfaces  300 , 310  may not be directly attached or welded to each other to facilitate removal or replacement of the inner fender structure. In at least one alternate embodiment, one or more additional fasteners may be located below the arm portion to further couple the inner fender structure to a closure frame structure. 
   Referring again to  FIGS. 13 and 14 , the first and second closure structures  260 , 262  may be pivotally disposed on the first and second closure frame structures  256 , 258 , respectively. In at least one embodiment, the closure structures  260 , 262  may each include a closure hinge portion  320 . 
   The closure frame hinge portions  298  and closure hinge portions  320  may have any suitable configuration. In the embodiment shown in  FIGS. 13 and 14 , the hinge portions  298 , 320  may be generally aligned with each other. Each hinge portion  298 , 320  may have an upper wall  322 , a lower wall  324 , and at least one side wall  326  that may cooperate to define a pocket  328 . The upper and lower walls  322 , 324  may each have a hole  330 . The holes  330  may generally be disposed along an axis. In at least one other embodiment, such as that shown in  FIG. 16 , closure frame and closure hinge portions  298 ′, 320 ′ may have a single wall that includes a hole  330 ′. 
   Referring to  FIGS. 17 and 18 , an exemplary connection between the hinge portions  298 , 320  is shown. The connection may include various components that permit the hinge portions  298 , 320  to receive a hinge pin  340  and permit a closure structure to pivot with respect to a closure frame structure without binding. In  FIG. 18 , the hinge pin  340  is not shown for clarity. In addition to the hinge pin  340  the hinge portion connection components may include a first bushing  342 , a second bushing  344 , a shim  346 , and a cover  348 . 
   The first bushing  342  may be received by at least one hole  330 . The first bushing  342  may include a body portion  350  and a flange portion  352  disposed proximate the body portion  350 . The body portion  350  may have any suitable configuration. In the embodiment shown, the body portion  350  is generally cylindrical and includes a through hole  354  that may receive the hinge pin  340 . The flange portion  352  may extend outwardly and may help position the first bushing  342  with respect to a hinge portion. The flange portion  352  may include a recess  356  that at least partially receives at least one other connection component as will be described in more detail below. In addition, the body and/or flange portions  350 , 352  may be disposed about a bushing axis  358 . 
   The second bushing  344  may have a similar configuration as the first bushing  342 . The second bushing  344  may include a body portion  360  and a flange portion  362 . The body portion  360  may include a through hole  364  that receives the hinge pin  340 . The flange portion  362  may engage the first bushing  342 . In at least one embodiment, the flange portion  362  may be at least partially received in the recess  356 . 
   The shim  346  may be disposed between the first and second bushings  342 , 344 . In at least one embodiment, the shim  346  may be disposed in the recess  356  and may include a through hole  370 . The through hole  370  may be disposed about a hole axis  372  that may be offset from the center of the shim  346  and may be offset from the bushing axis  358 . In addition, the shim  346  may include a notch  374  that receives the flange portion  362  of the second bushing  344  as is best shown in  FIG. 18 . The through hole  370  may receive the second bushing  344  while a perimeter surface  376  of the shim  346  may engage the flange portion  352  or recess wall of the first bushing  342 . As such, the shim  346  may facilitate alignment of the first and second bushings  342 , 344 . For example, the shim  346  may be rotated with respect to the first bushing  342  to adjust the position of the second bushing  344 , thereby helping to align the bushings  342 , 344  and accommodate misalignment of the holes  330 . Shims may be provided in one or more sizes (e.g., thicknesses and/or through hole locations) to accommodate different adjustment needs. 
   The cover  348  may be disposed proximate the first bushing  342  and may help hold the second bushing  344  and/or shim  346  adjacent to the first bushing  342 . The cover  348  may have any suitable configuration. For example, the cover  348  may include a hook and loop fastener that facilitates attachment to the first bushing  342  and may accommodate rotation of the shim  346  and repositioning of the second bushing  344 . 
   Referring to  FIGS. 19-22  various embodiments of exemplary third zones  34  are shown. These embodiments may at least partially define a passenger compartment  24  of the vehicle  10 , such as an intermediate or rear portion disposed adjacent to the second zone  32 . 
   Referring to  FIG. 19 , a first embodiment of a third zone  34  is shown. This embodiment may be representative of a four door vehicle configuration. The third zone  34  may include a roof structure  400 , a second floor structure  402 , a first closure frame structure  404 , a second closure frame structure  406 , a first closure structure  408 , and a second closure structure  410 . 
   The roof structure  400  may at least partially define a roof of the vehicle  10 . For example, the roof structure  400  may extend between the first and second closure structures  404 , 406 . The roof structure  400  may receive one or more body panels and may include a sunroof or moonroof opening in one or more embodiments of the present invention. 
   The roof structure  400  may include a plurality of mating features that engage or interlock with another vehicle body structure component. For instance, the roof structure  400  may include first and second sets of roof mating features  420 , 422  that engage or interlock with the first and second closure structures  404 , 406 , respectively. The first and second sets of roof mating features may be disposed on a surface of the roof structure  400  that faces the passenger compartment  24 . The roof structure  400  may also include a third and fourth sets of roof mating features  424 , 426  that engage or interlock with a vehicle body structure component disposed in an adjacent zone, such as the second and fourth zones  32 , 36 , respectively. In at least one embodiment, the third and fourth sets of roof mating features  424 , 426  may be disposed along a front and rear surfaces of the roof structure  400 , respectively. The mating features  420 , 422 , 424 , 426  may have any suitable configuration as will be discussed in more detail below. 
   The second floor structure  402  may at least partially define a floor of the passenger compartment  24 . The second floor structure  402  may be disposed proximate or may be mounted to the first and second closure structures  404 , 406 . Additional features of the second floor structure  402  and other lower portion  20  components will be discussed in more detail below. 
   The first and second closure frame structures  404 , 406  may be disposed on opposite sides of the vehicle  10 . Each closure frame structure  404 , 406  may at least partially define an opening that receives a closure structure. The first and second closure frame structures  404 , 406  may include various features for mating with other vehicle body structure components. For example, the first and second closure frame structures  404 , 406  may each include hinge portions  298 , an upper mating feature  430 , and first and second structure mating features  432 , 434 . These mating features may be integrally formed with their respective closure frame structures in one or more embodiments of the present invention. 
   The upper mating features  430  of the first and second closure frame structures  404 , 406  may engage or interlock with the first and second roof mating features  420 , 422 , respectively. The upper mating features  430  may have any suitable configuration that is compatible with the first and second roof mating features  420 , 422 . 
   The first and second structure mating features  432 , 434  may engage or interlock with vehicle body structure components disposed in adjacent zones, such as the second and fourth zones  32 , 36 , respectively. In at least one embodiment, the structure mating features  432 , 434  may be disposed along front and rear surfaces of the closure frame structures  404 , 406 , respectively, and may have any suitable configuration as will be discussed in more detail below. 
   The first and second closure structures  408 , 410  may be pivotally disposed on the first and second closure frame structures  404 , 406 , respectively. The closure structures  408 , 410  may have a configuration similar to closure structures  260  and  262 . As such, each closure structure  408 , 410  may each include a closure hinge portion  320  as previously described. 
   Referring to  FIG. 20 , a second embodiment of a third zone is shown. This embodiment may be representative of a regular cab pickup configuration and may include a rear structure  440  that may include a plurality of mating features  442  that engage vehicle body structure components associated with the second zone  32 . In at least one embodiment, the mating features  442  may face toward the front of the vehicle for engaging the roof structure  250  and first and second closure frame structures  256 , 258  of the second zone  32 . For example, one or more mating features  442  may engage or interlock with third set of roof mating features  274  and the structure mating features  292 . In addition, one or more mating features  442  may be adapted to engage part of the lower portion  20 , such as the first floor structure  254  in one or more embodiments of the present invention. In  FIG. 20 , the second floor structure  402  is not shown for clarity. 
   Referring to  FIG. 21 , a third embodiment of a third zone is shown. This embodiment may be representative of an extended cab pickup configuration having at least one closure. The third embodiment may be provided by combining the roof structure  400 , a second floor structure  402 , and components similar to the closure frame structures  404 , 406 , and closure structures  408 , 410  with the rear structure  440  of  FIG. 20 . For example, the rear structure mating features  442  may engage or interlock with the fourth set of roof mating features  426  and structure mating features  434 . In  FIG. 21 , the second floor structure  402  is not shown for clarity. 
   Referring to  FIG. 22 , a fourth embodiment of a third zone is shown. This embodiment may be representative of an extended cab pickup configuration. The fourth embodiment may be provided by combining a roof structure  400 ′, a second floor structure  402 , and side frame structures  404 ′, 406 ′ with the rear structure  440 . In  FIG. 22 , the second floor structure  402  is not shown for clarity. At least one of the side frame structures  404 ′, 406 ′ may not include a closure opening in one or more embodiments of the present invention. 
   Referring to  FIGS. 23-26  various embodiments of exemplary fourth zones  36  are shown. These embodiments may at least partially define a rear portion of the vehicle  10 . 
   Referring to  FIG. 23 , a first embodiment of a fourth zone  36  is shown. This embodiment may be representative of a van, sport utility, or hatchback vehicle configuration. The fourth zone  36  may include a roof structure  500 , a third floor structure  502 , a first side structure  504 , a second side structure  506 , a rear structure  508 , and a rear closure structure  510 . 
   The roof structure  500  may at least partially define a roof of the vehicle  10  and may extend between the first and second side structures  502 , 504 . The roof structure  500  may include a plurality of mating features that engage or interlock with another vehicle body structure component. For instance, the roof structure  500  may include first and second sets of roof mating features  520 , 522  that engage or interlock with the first and second side structures  504 , 506 , respectively. The roof structure  500  may also include a third and fourth sets of roof mating features  524 , 526  that engage or interlock with a vehicle body structure component. In at least one embodiment, the third and fourth sets of roof mating features  524 , 526  may be disposed along a front and rear surfaces of the roof structure  500 , respectively. The mating features  520 , 522 , 524 , 526  may have any suitable configuration as will be discussed in more detail below. 
   The third floor structure  502  may be disposed proximate various structural components, such as the first and second closure structures  504 , 506  and/or the rear structure  508 . Additional features of the third floor structure  502  will be discussed in more detail below. 
   The first and second side structures  504 , 506  may be disposed on opposite sides of the vehicle  10 . Each side structure  504 , 506  may be provided with or without window openings. The first and second side structures  504 , 506  may include various features for mating with other vehicle body structure components. For example, the first and second side structures  504 , 506  may each include an upper mating feature  530  and first and second structure mating features  532 , 534 . These mating features may be integrally formed with the side structures. 
   The upper mating features  530  of the first and second side structures  504 , 506  may engage or interlock with the first and second roof mating features  520 , 522 , respectively. The upper mating features  530  may have any suitable configuration that is compatible with the first and second roof mating features  520 , 522 . These mating features may be integrally formed with the side structures. 
   The first and second structure mating features  532 , 534  may engage or interlock with a vehicle body structure component. These mating features may be integrally formed with the side structures. In at least one embodiment, the structure mating features  532 , 534  may be disposed along front and rear surfaces of the side structures  520 , 522 , respectively, and may have any suitable configuration as will be discussed in more detail below. 
   The rear structure  508  may include various features for mating with other vehicle body structure components. For example, the rear structure  508  may include mating features  540  that engage or interlock with the fourth set of roof mating features  526  and/or structure mating features  534 . In addition, the rear structure  508  may also include mating features that engage or interlock with the third floor structure  502 . The rear structure  508  may also include hinge portions  298  that facilitate pivotal attachment of the rear closure structure  510 . The hinge portions  298  may be disposed proximate any side of an opening  542  provided in the rear structure  508  to accommodate various closure structure configurations and/or pivotal window attachments. 
   The rear closure structure  510  may be pivotally disposed on the rear structure  508 . The rear closure structure  510  may have any suitable configuration, such as a liftgate or one or more doors. In at least one embodiment, the rear closure structure  510  may include a closure hinge portion  320 . 
   Referring to  FIG. 24 , a second embodiment of a fourth zone is shown. This embodiment may be representative of a sedan configuration and may include an upper structure  550 , a first rear side structure  552 , a second rear side structure  554 , and a rear closure structure  556 . This embodiment may also include the third floor structure  502 , which is not shown for clarity. 
   The upper structure  550  may be provided proximate upper and/or rear surfaces of the vehicle  10 . The upper structure  550  may include various features for mating with other vehicle body structure components. For example, the upper structure  550  may include first, second, and third sets of frontal mating features  560 , 562 , 564 . In at least one embodiment, the first set of frontal mating features  564  may interlock with the fourth set of roof mating features  426 . In addition, the upper structure  550  may include one or more hinge portions  298  disposed proximate an opening  566  to facilitate pivotal mounting of the rear closure structure  556 . 
   The first and second rear side structures  552 , 554  may be disposed on opposite sides of the vehicle  10 . The first and second rear side structures  552 , 554  may include various features for mating with other vehicle body structure components. For example, the first and second side structures  552 , 554  may each include first and second sets of upper mating features  570 , 572  and a set of passenger compartment mating features  574 . These mating features may be integrally formed with the side structures. 
   The first and second sets of upper mating features  570 , 572  may engage or interlock with the first and second sets of frontal mating features  560 , 562 , respectively. The upper mating features  570 , 572  may have any suitable configuration that is compatible with the first and second frontal mating features  560 , 562 . In at least one embodiment, the first and second sets of upper mating features  570 , 572  may generally be disposed along upper surfaces of the first and second side structures  552 , 554 . 
   The passenger compartment mating features  574  may engage or interlock with a vehicle body structure component. In at least one embodiment, the passenger compartment mating features  574  may be disposed along front surfaces of the first and second side structures  552 , 554  and may interlock with structure mating features  434 . The passenger compartment mating features  574  may have any suitable configuration as will be discussed in more detail below. 
   The rear closure structure  556  may be pivotally disposed on the upper structure  550 . The rear closure structure  556  may have any suitable configuration, such as a trunk lid. In at least one embodiment, the rear closure structure  556  may include a closure hinge portion  320  and a hinge connection as previously described. 
   Referring to  FIG. 25 , a third embodiment of a fourth zone is shown. This embodiment may be representative of a hatchback configuration and may include an upper structure  580  and a rear closure structure  582 . This embodiment may also include the third floor structure  502 , which is not shown for clarity. 
   The upper structure  580  may include various features for mating with other vehicle body structure components. For example, the upper structure  580  may include first, second, and third sets of frontal mating features  560 ′, 562 ′, 564 ′. In at least one embodiment, the first and second sets of frontal mating features  560 ′, 562 ′ may engage or interlock with the first and second sets of upper mating features  570 , 572  while the third set of frontal mating features  564 ′ may interlock with the fourth set of roof mating features  426 . In addition, the upper structure  580  may include one or more hinge portions  298  disposed proximate an opening  566 ′ to facilitate pivotal mounting of the rear closure structure  582 . 
   The rear closure structure  582  may be pivotally disposed on the upper structure  580 . The rear closure structure  582  may have any suitable configuration, such as a hatchback lid. In at least one embodiment, the rear closure structure  582  may include a closure hinge portion  320  and a hinge connection as previously described. 
   Referring to  FIG. 26 , a fourth embodiment of a fourth zone is shown. This embodiment may be representative of a pickup truck configuration and may include the third floor structure  502 ′, first rear side structure  600 , a second rear side structure  602 , a rear structure  604 , and a rear closure structure  606 . 
   The third floor structure  502 ′ may be disposed proximate various structural components, such as the first and second rear side structures  602 , 604  and rear structure  608 . In the embodiment shown, the third floor structure  502 ′ is configured as variation of the third floor structure  502 . For example, the third floor structure  502 ′ may include a plurality of rear end mating features  610  that may engage the rear structure  604 . It should be understood that either third floor structures  502 , 502 ′ may be used in one or more embodiments of the present invention. 
   The first and second rear side structures  600 , 602  may be disposed on opposite sides of the vehicle  10 . The first and second side structures  600 , 602  may include various features for mating with other vehicle body structure components. For example, the first and second side structures  600 , 602  may each include structure mating features  612  that may be integrally formed with the rear side structures  600 , 602 . The structure mating features  612 , if provided, may be disposed along front surfaces of the rear side structures  600 , 602 , respectively. In at least one embodiment, the structure mating features  612  may engage or interlock with mating features associated with another zone, such as a rear structure  440 , and may have any suitable configuration as will be discussed in more detail below. In addition, the first and second side structures  600 , 602  may have mating features that interlock with the rear end structure  604  and/or third floor structure  502 ′ in one or more embodiments of the present invention. 
   The rear structure  604  may include various features for mating with other vehicle body structure components. For example, the rear structure  604  may include mating features  614  that engage or interlock with the plurality of rear end mating features  610 . In addition, the rear structure  604  may also include features that facilitate pivotal attachment of the rear closure structure  606 . 
   The rear closure structure  606  may be pivotally disposed on the first and second rear side structures  600 , 602  or the rear structure  604  as shown in  FIG. 26 . The rear closure structure  606  may have any suitable configuration, such as a tailgate or side mounted closure. 
   Referring to  FIG. 27 , an exemplary embodiment of an interlocking floor assembly  700  is shown. The interlocking floor assembly  700  may include a set of floor structure components. In at least one embodiment, the members of the set of floor structure components may be castings and may be made of any suitable material, such as a magnesium or aluminum alloy. In the embodiment shown in  FIG. 27 , the set of floor structure components includes first, second, and third floor structures  254 , 402 , 502 . 
   The members of the set of floor structure components may include one or more sets of mating features that engage or interlock with at least a portion of one other set of mating features to couple the floor structure components together. These mating features may be integrally formed. In at least one embodiment, coupling may be accomplished without welding. In addition, the interlocking mating features may permit a vehicle to be provided without a frame of welded steel components. The mating features may have any suitable configuration as will be discussed in more detail below. 
   The first floor structure  254  may include a first set of mating features  702  and at least one tunnel. In the embodiment shown, a first tunnel  704  is shown, although additional tunnels may be provided in one or more embodiments of the present invention. For example, additional tunnels may be disposed near one or more sides of the first floor structure  254  to help provide structural rigidity. Such side tunnels may generally extend in a longitudinal direction and may have a smaller size than the first tunnel  704  to provide a generally flat floor surface near an occupant seating location. The first set of mating features  702  may be disposed proximate an end of the first floor structure  254  and may be disposed proximate the first tunnel  704 . 
   The first tunnel  704  may extend between opposing ends of the first floor structure  254 . In the embodiment shown, the first tunnel  704  is generally located near the middle of the first floor structure  254  and may provide a passage into which various components, such as a transmission, drive shaft, or conduits may extend. 
   The second floor structure  402  may include second and third sets of mating features  710 , 712  and a second tunnel  714 . The second set of mating features  710  may engage or interlock with the first set of mating features  702 . The second and third sets of mating features  710 , 712  may be disposed proximate opposite ends of the second floor structure  402 . In at least one embodiment, at least one of the second and third sets of mating features  710 , 712  may be disposed proximate the second tunnel  714 . In addition, the second and third sets of mating features  710 , 712  may be disposed in different planes. In the embodiment shown in  FIG. 27 , the second set of mating features  710  is generally disposed near a bottom surface of the second floor structure  402  while the third set of mating features  712  may be disposed near an upper surface of the second floor structure  402  and above the second set of mating features  710 . 
   The third floor structure  502  may include a fifth set of mating features  720 . The fifth set of mating features  720  may be disposed proximate an end of the third floor structure  502  and may engage or interlock with the fourth set of mating features  712 . In at least one embodiment, the third floor structure  502  may include at least a portion of a wheel well of a vehicle  10 . 
   Referring to  FIG. 28 , an exemplary interface between the first and second tunnels  704 , 714  is shown. A portion of the first tunnel  704  may be received by the second tunnel  714  or vice versa. In addition, at least one of the first and second tunnels  704 , 714  may include first and second sets of tunnel mating features  730 , 732  and/or a cuff  734 . Similar features may be provided with additional tunnels and/or between if provided. 
   The first and second sets of tunnel mating features  730 , 732  may engage or interlock to help seal or inhibit fluid leakage between the first and second floor structures  254 , 402 . The tunnel mating features  730 , 732  may have any suitable configuration. For example, the tunnel mating features  730 , 732  may have any combination of male or female configurations. In the embodiment shown, the first set of mating features  730  are configured as ribs that extend from an upper surface of the first tunnel  704  while the second set of mating features  732  are configured as grooves that receive the first set of mating features  704  and are disposed on a lower surface of the second tunnel  714 . 
   At least one cuff  734  may be disposed proximate a tunnel. In the embodiment shown, cuffs  734  are disposed on opposite sides of the first tunnel  704 . The cuffs  734  may receive and/or position the second tunnel  714  with respect to the first tunnel  704 . In addition, the cuffs  734  may be curve or extend upwardly to help inhibit fluids from entering between the first and second floor structures  254 , 402 . 
   The first, second, and/or third floor structures  254 , 402 , 502  may include at least one storage compartment  740 . The storage compartments  740  may be integrally formed in a floor structure and may extend from an upper surface of an associated floor structure. Storage compartments may be configured to receive foldable seats, spare tires, storage bins, or the like. 
   Various exemplary embodiments of mating features that may be provided with vehicle body structure components will now be described in more detail. In at least one embodiment, similarly configured mating features may mate or interlock together to couple vehicle body structure components together. As such, a vehicle body structure  14  or a portion thereof may be assembled without welding. The mating features may be integrally formed with a body structure component, such as by casting. In at least one embodiment, a first type of mating feature may be associated with the engine compartment  20  while a second type of mating feature may be associated with other vehicle areas, such as the passenger compartment  22 . In at least one other embodiment, a first type of mating feature may be associated with the engine compartment  20  while second and third types of mating features may be associated with a passenger compartment  22 . For example, the passenger compartment  22  may include a second type of mating feature, such as a dovetail mating feature, for connecting most vehicle body structure components, and a third type of mating feature for connecting panels that at least partially define a roof structure to other vehicle body structure components, such as the sides or closure frame structures. In addition, sets of mating features associated with one or more body structure components may be oriented to enable or allow multiple sets of mating features to be engaged simultaneously to facilitate assembly. 
   The mating features may be configured to interlock and inhibit movement in one or more directions. For example, the mating features may be configured to inhibit movement along multiple axes and in multiple directions that differ from the direction in which one mating feature is inserted into another. 
   Referring to  FIG. 29 , one embodiment of a set of mating features  750  is shown. Such a mating feature may be provided in any suitable location, such as at an interface between a roof or upper structure and the sides of the vehicle. The mating feature  750  may include a male portion  752  that is received by a female portion  754 . The male portion  752  may include one or more enlarged sections  756  that facilitate interlocking or engagement with the female portion  754 . The female portion  754  may include one or more openings for receiving the male portion  752 . The openings may have any suitable configuration. In the embodiment shown, a single opening  758  is provided; however, the present invention also contemplates embodiments having a plurality of enlarged openings that may each receive an enlarged section  756 . The male portion  752  may be adapted to slide or move relative to the female portion  754  to permit engagement of multiple sets of mating features in a predetermined manner or sequence. 
   Referring to  FIG. 30 , one embodiment of a mating feature  800  having a dovetail configuration is shown. The mating feature  800  may include male and female portions  802 , 804 . 
   The male portion  802  may extend from a vehicle body structure component. In at least one embodiment, the male portion  802  may include a first surface  810 , a second surface  812 , a first joint surface  814 , a second joint surface  816 , and a connecting surface  818 . 
   The male portion  802  may include one or more edges or surfaces that extend along intersecting planes. In at least one embodiment, the male portion  802  may have a generally trapezoidal cross section. The male portion  802  may be tapered in multiple directions. In the embodiment shown in  FIG. 30 , the male portion  802  is tapered from front to back such that the front edge X is longer than the back edge X′. As such, the first and second joint surfaces  814 , 816  may be tapered in a direction that extends away from the connecting surface  818 . In addition, the male portion  802  may be tapered from top to bottom such that the top edge Y is longer than the bottom edge Y′. As such, the first and second joint surfaces  814 , 816  may be tapered in a direction that extends away from the first surface  810 . Of course, the present invention also contemplates embodiments that are not tapered in one or more directions or tapered in directions that differ from those shown in  FIG. 30 . For instance, the male portion may be tapered from back to front and/or bottom to top in one or more embodiments of the present invention. An example of an embodiment in which the male and female portions are not tapered in a direction extending toward the vehicle body structure is shown in  FIG. 31 . In this embodiment, the first and second joint surfaces  814 ′, 816 ′ associated with the male and female portions  802 ′, 804 ′ are not tapered in a direction extending from the connecting surface  818 ′ toward an end surface  840 ′. 
   The male portion  802  may also include a channel  820 . The channel  820  may be adapted to receive or provide an adhesive to one or more mating feature surfaces as will be described in more detail below. In at least one embodiment, the channel  820  may extend between the first and second surfaces  810 , 812 . In addition, the channel  820  may narrow or generally follow the contour or tapering of one or more surfaces of the male portion  802 . In the embodiment shown in  FIG. 30 , the channel  820  includes first and second pockets  830 , 832 . The first and second pockets  830 , 832  may be are disposed adjacent to each other and may be configured such that the first pocket  830  has a larger volume than the second pocket  832 . In addition, the channel  820  may be disposed proximate an indentation  834  associated with the second surface  812 . 
   The female portion  804  may be configured to receive a male portion  802  of a mating feature that is provided with another vehicle body structure component. One or more male portions  802  may be disposed adjacent to each female portion  804 . The female portion  804  may be at least partially defined by first and second joint surfaces  814 , 816  that are associated with different male portions  802 . In addition, the female portion  804  may include an end surface  840  and a protrusion  842 . The end surface  840  may extend from or between one or more male portions  802 . The protrusion  842  may extend from the end surface  840  and may be received by an indentation  834  to help locate and position mating male and female portions  802 , 804 . In the embodiment shown in  FIG. 30 , the protrusion  842  is spaced apart from joint surfaces  814 , 816  that help define the female portion  804 . 
   A ledge or cap surface  850  may be associated with one or more mating features. The cap surface  850  may be disposed proximate an end of one or more female portions  804  and may extend from one or more male portions  802 . For example, the cap surface may extend at least partially across an end of one or more female portions  804  as shown on the right side of  FIG. 30 . As such, the cap surface  850  may help enclose the mating features, inhibit fluid ingression between adjoining mating feature surfaces, and may provide improved strength. In at least one embodiment, the protrusion  842  may extend from the cap surface  850 . 
   Referring to  FIG. 32 , another embodiment of a mating feature having a dovetail configuration is shown. In this embodiment, the mating feature  800 ″ may include male and female portions  802 ″, 804 ″ having generally trapezoidal cross sections. The male portion  802 ″ may extend from a vehicle body structure component and may be at least partially defined by first and second walls  806 ″, 808 ″. The first and second walls  806 ″, 808 ″ may include first and second joint surfaces  814 ″, 816 ″, respectively. The first and second joint surfaces  814 ″, 816 ″ may be tapered relative to each other as previously discussed. A channel  820 ″ may be disposed between the first and second joint surfaces  814 ″, 816 ″. The walls  806 ″, 808 ″ may extend from a ledge or cap surface  850 ″ to help support the walls  806 ″, 808 ″ to help distribute load forces in one or more embodiments of the present invention. 
   Referring to  FIGS. 33 and 34 , various other exemplary embodiments of mating features having a dovetail configuration are shown. In  FIG. 33 , the male and female portions  860 , 862  have similar configurations. The male portion  860  may include an extension feature  864  disposed between a vehicle body structure component and an enlarged region  866  that interlocks with the female portion  862 . The enlarged region  866  may have any suitable configuration. For example, the enlarged region  866  may extend outwardly from the extension feature  864  in one or more directions. For instance, in the embodiment shown in  FIG. 34 , the enlarged region  866 ′ extends away from the extension feature  864 ′ and from an upper surface  868 ′ of the male portion  860 ′ and may include a non-planar surface that engages a female portion  862 ′ having a compatible configuration. 
   The mating features previously discussed may be provided in various arrangements. For example, the mating features may be provided in one or more rows to provide additional interlocking surfaces and to further distribute load forces. Rows may be provided in any suitable manner. For example, in the embodiment shown in  FIG. 35 , first and second rows  870 , 872  of dovetail mating features are provided. The rows  870 , 872  may be positioned such that one or more mating features in each row are aligned with each other. Alternatively, one or more rows  870 ′, 872 ′ of mating features may be provided that have at least some mating features that are staggered or offset from those in another row as shown in  FIG. 36 . Rows may be disposed adjacent to each other or spaced apart in one or more embodiments of the present invention. 
   An adhesive may be provided to help bond, fill, and/or seal mating interfaces together. For simplicity, the term adhesive will be used to generically refer to any material or materials that provide one or more of the aforementioned functions. In at least one embodiment, a heat catalyzed mastic material may be employed to fill any gaps between mating surfaces. The adhesive may be provided in any suitable manner. For example, the adhesive may be applied to one or more surfaces of a mating feature before, during or after the mating features are interlocked. In at least one embodiment, the adhesive may be provided via a channel  820  as previously discussed. In addition, the adhesive may facilitate repair or replacement of vehicle body structure components. For example, in at least one embodiment the adhesive may be softened through the application of heat to permit components to be separated. 
   The vehicle body structure  10  may be assembled by interlocking or engaging mating features in any suitable manner. In at least one embodiment, a subset of vehicle body structure components may be assembled together to form subassemblies that may then be assembled to create a vehicle body structure. For example, vehicle body structure components may be assembled to create the upper portion  18  and lower portion  20 , then the upper and lower portions  18 , 20  may be assembled together to create the vehicle body structure  10 . In at least one embodiment, the upper portion  18  may be attached to the lower portion  20  in any suitable manner, such as by engaging or interlocking additional mating features or with one or more fasteners. In other embodiments, subassemblies may be provided by assembling roof, sides, or zones of body structure components together, and then assembling the subassemblies to create the vehicle body structure  10 . 
   Assembling a vehicle body structure with interlocking components may reduce or eliminate equipment and labor associated with body panel stamping and body shop operations in which multiple sheet metal components are welded together to create a vehicle body. In addition, interlocking components may enable a vehicle assembly plant to construct multiple vehicle body styles on a common assembly line. For example, multiple vehicle types like those shown in  FIGS. 37   a - 37   d  may share one or more vehicle body structure components. Moreover, an interlocking vehicle body structure may permit vehicles to be reconfigured into another vehicle style or type. For instance, a vehicle make be reconfigured from a sedan configuration  880  to a station wagon configuration  882 , sport utility/crossover vehicle configuration  884 , or a pickup truck configuration  886  by replacing select third and fourth zone vehicle body structure components and body panels. The present invention also contemplates that one or more components in any zone may be replaced or reused to provide additional vehicles or vehicle configurations. 
   Referring to  FIG. 38 , an exemplary body panel  900  is shown. The body panel  900  may be configured to cover at least a portion of at least one vehicle body structure component. For example, a plurality of body panels may be disposed on the upper portion  18  of the vehicle body structure  14  and may form an exterior surface of the vehicle  10 . The body panels may have any suitable configuration and may be made of any suitable material. For instance, one or more body panels may be made of a polymeric material and may be configured to flex to facilitate mounting and/or removal. In addition, the body panels  900  may be provided with one or more molded-in colors to reduce or eliminate painting or coating of a body panel and reduce associated labor, equipment, and facility costs. 
   Each body panel  900  may include a first surface  902  and a second surface  904  disposed opposite the first surface  902 . The first surface  902  may form an exterior vehicle surface. The second surface  904  may face toward one or more vehicle body structure components. The second surface  904  may include one or more stiffening features  906  that help the body panel  900  retain a desired shape and may provide additional support by engaging a vehicle body structure component. In addition, each body panel  900  may include at least one mating feature  908 . The mating features  908  may be disposed proximate any suitable surface. In at least one embodiment, the stiffening features  906  and mating features  908  may be integrally formed with the body panel  900  and may extend from or into the second surface  904 . 
   The mating features  908  may have any suitable configuration, such as a male configuration, female configuration, or combinations thereof. In the embodiment shown in  FIG. 38 , a plurality of mating features  908  extend from the second surface  904  and are disposed near a perimeter of the body panel  900 . As such, one or more mating features  908  may also provide localized stiffening of the body panel  900 . In at least one embodiment, a mating feature may in a generally continuous manner relative to one or more sides of the body panel. For instance, a mating feature  908 ′ may extend into or away from a body panel  900 ′ and may extend in a ringlike manner around a portion of the body panel  900 ′ as shown in  FIG. 39  to provide a seal that inhibits moisture from passing between the body panel  900 ′ and at least one associated vehicle body structure component. In at least one embodiment, the mating feature  908 ′ may also include a second ring  908 ″ that can accommodate an associated body mating feature having a male and/or a female configuration. 
   Referring again to  FIG. 38 , the body panel  900  may include a set of hinge covers  920 . The set of hinge covers  920  may be disposed along a side of the body panel  900  any may be configured to at least partially conceal a closure hinge area. The members of the set of hinge covers  920  may be spaced apart from each other to create a gap  922 . A portion of a hinge cover disposed on another body panel may extend into the gap  922  as is best shown in  FIG. 1 . 
   One or more members of the set of hinge covers  920  may include at least one flange  924  that extends away from the second surface  904  and further facilitates mounting of the body panel  900 . The flange  924  may include an aperture  926  through which the hinge pin  340  of a closure hinge may extend. The flange  924  may be disposed proximate an associated hinge portion, such as hinge portions  298  or  320 , when the body panel is assembled to the vehicle body structure  14 . For example, the flange  924  may be disposed proximate a pocket  328  of a hinge portion  298 , 320  as represented in  FIG. 40 . In at least one embodiment, a plurality of flanges  924  may extend from a hinge cover  920  and may be disposed proximate opposing walls that at least partially define the pocket  328  as shown in  FIG. 41 . 
   Referring to  FIG. 42 , a magnified view of an exemplary connection between a body panel  900  and a vehicle body structure component is shown. Reference number  930  will be used to generically refer to a vehicle body structure component since multiple body structure components may engage at least one body panel. 
   In the embodiment shown, the body panel  900  includes a body panel mating feature  908  having a male configuration and the vehicle body structure component  930  includes a body structure mating feature  932  having a female configuration. The body structure mating feature  932  may partially or completely extend into the body structure component in one or more embodiments of the present invention. 
   The body panel mating feature  908  may protrude from the body panel  900  and may include a hole  934 . The body structure mating feature  932  may be configured as a groove having at least one hole  938  that may be coaxially aligned with hole  934 . A fastener  940  may extend through at least one hole  938  in the body structure component  930  and the hole  934  in the body panel  900  to inhibit removal of the body panel  900 . Installation of the fastener  940  may be facilitated by an opening provided in a vehicle body structure component  930 . For instance, the fastener  940  may be inserted through an opening that faces the engine or passenger compartment  22 , 24  rather than through an opening in the body panel  900  in one or more embodiments of the present invention. Such embodiments may inhibit unintended or unauthorized removal of a body panel since access to the interior of the vehicle may be needed to access a fastener. 
   Referring to  FIGS. 43 and 44 , additional exemplary connections between a body panel and a vehicle body structure component is shown. In the embodiment shown in  FIG. 43 , the body panel  900  includes a body panel mating feature  908 ′ having a female configuration and the vehicle body structure component  930  includes a body structure mating feature  932 ′ having a male configuration. A fastener  940  may extend through at least one hole  934  in the body panel  900  and the hole  938  in the body structure component  930  to inhibit removal of the body panel  900 . In the embodiment shown in  FIG. 44 , the fastener  940 ′ may extends through a hole in the body structure mating feature  932 ″ and may engage the body panel mating feature  908 ″ to couple or otherwise inhibit removal of the body panel  900 . 
   Referring to  FIGS. 45 and 46 , additional views of a vehicle body panel are shown. The body panel  900  may include a flexible rim  950  may at least partially define a perimeter surface of the body panel  900  and may generally extend from a body panel mating feature  932 , 932 ′. In at least one embodiment, the flexible rim  950  may include an end portion  952  that extends toward the vehicle body structure  14 . 
   The body panel  900  may be adapted to accommodate expansion and/or contraction of one or more vehicle surfaces or components. For example, the flexible rim  950  may extend toward and contact a vehicle body component, such as a window  954 , and may flex to accommodate movement and/or help the body panel  900  maintain contact with the window  954  to inhibit moisture ingression. In addition, a gap  956  may be disposed the body panel mating feature  932 , 932 ′ and the window  954  to accommodate expansion and contraction. The gap  956  may also disposed adjacent to an edging member  958  that is associated with the vehicle body component. The edging member  958  may include a window groove  960  for receiving the window  954 , which may be configured to guide movement of the window  954 . The edging member  958  may be attached to another component, such as a body structure component  930  in any suitable manner. 
   The connection structures and techniques described above may permit a body panel to be assembled to a vehicle body structure free of welding. Moreover, the connection structures and techniques may provide flexibility in vehicle assembly processes as body panels may be assembled to one or more body structure components either before or after assembly of a portion of the vehicle body structure  14 . Such flexibility may help improve equipment and assembly plant utilization and provide associated cost advantages. In addition, the connection structures and techniques may permit a body panel to be easily removed and replaced, thereby enabling changes to a vehicle color or configuration after initial assembly. For example, vehicle purchasers or dealers may remove and replace body panels to provide a different vehicle appearance or accommodate the installation of different vehicle body structure components. In addition, in at least one embodiment of the present invention, servicing and/or replacement of vehicle components may be improved. For example, parts that may be more likely to be damaged may be configured to be easily repaired and/or accessed. 
   While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.