Abstract: A side impact protection device for a vehicle packaged between inner and outer panels such as door panels in the door includes a load-bearing member rigidly attached with respect to an inner surface of a side outer panel and extending inward towards a side inner panel. The load-bearing member is configured to deflect a side impact load away from a portion of the side inner panel located between the load-bearing member and a rearward edge of the side outer panel. In some embodiments, the load-bearing member permits compliant flexing of the door inner panel by partially forming a cavity into which the door inner panel may flex when the side impact load is deflected by the load-bearing member.

Abstract: A structural assembly for a vehicle includes a structural member extending longitudinally. The structural assembly also includes an insert disposed within and extending longitudinally along at least a portion of the structural member and having at least one corrugation to act as a crush initiator during an axial impact on the structural assembly.

Abstract: A rail assembly for a vehicle includes a rail member extending longitudinally. The rail assembly also includes an insert disposed within and extending longitudinally along at least a portion of the rail member and having at least one curved section to provide load carrying capacity in the rail member.