Patent ID: 8196958

Claim:
A frame assembly for a vehicle, comprising: two frame rails that extend parallel to one another, wherein each of the two frame rails are C-shaped in cross-section and each comprises a vertically-extending web, a horizontally-extending top flange extending from the web, and a horizontally-extending bottom flange extending from the web; wherein each of the frame rails has a first outer steel layer, a second outer steel layer, and an aluminum core layer metallurgically roll-bonded between the first outer steel layer and the second outer steel layer to form a C-shape in cross-section; wherein in cross-section, the first steel layer and the second steel layer are coextensive with the aluminum core layer over the frame rails with exception to a first portion and a second portion at ends of the C-shape that are not enclosed the first steel layer and the second steel layer; a plurality of cross-members that extend transversely between and are fixedly attached to the two frame rails.