Recyclable, low cost, collision-resistant automobile chassis and body

A method of manufacturing a recyclable automobile chassis, comprising the steps of:

• fabricating a plurality of generally planar bulkheads from a metal alloy;
• disposing the bulkheads in a generally and mutually parallel orientation, each bulkhead being situated generally perpendicularly to and aligned generally transversely and symmetrically relative to a common central horizontal longitudinal axis;
• fabricating a plurality of chassis segments, each segment formed by providing a sheet of metal alloy comprising a multiplicity of spaced hollow cells fixed at one end in a common surface, the sheet being formed with protrusions by forcing portions of said sheet out of the surface of said sheet to project as closed thinwall projections defining said spaced hollow cells;
• interposing and rigidly attaching at least one of said pluralities of chassis segments between respective bulkheads to form a plurality of self-aligning chassis sections, a section defined as the portion of the fabricated chassis between two adjacent bulkheads;
• and
• permeating the plurality of chassis sections with liquefied polymer between and around the hollow cells.

An automobile chassis comprising:

• a plurality of generally planar bulkheads;
• a plurality of chassis segments, each segment having formed therein a multiplicity of spaced, outwardly projecting hollow cells, the hollow cells being fixed at one end to form a common surface, and each segment being interposed and rigidly attached between respective bulkheads to form a plurality of self-aligning chassis sections, a section defined as the portion of the fabricated chassis between two adjacent bulkheads;
• and
• a liquefied polymer permeating the plurality of chassis sections between and around said hollow cells.

A method of manufacturing a recyclable automobile chassis, comprising the steps of:

• fabricating a plurality of generally planar bulkheads from a metal alloy;
• disposing the bulkheads in a generally and mutually parallel orientation, each bulkhead being situated generally perpendicularly to and aligned generally transversely and symmetrically relative to a common central horizontal longitudinal axis;
• fabricating a plurality of chassis segments from a metal alloy, each segment comprising a multiplicity of spaced hollow cells fixed at one end in a common surface;
• and
• interposing and rigidly attaching at least one of said pluralities of chassis segments between respective bulkheads to form a plurality of self-aligning chassis sections, a section defined as the portion of the fabricated chassis between two adjacent bulkheads.