Abstract: A reinforcement beam for a vehicle has an outer beam profile and an inner beam profile. The outer beam profile define an elongated hollow body and includes a front wall portion and a rear wall portion. The outer beam profile may include upper and lower flanges that formed in planar extension of the font wall portion. The inner beam profile may include a C-shape defining an upper shear wall and a lower shear wall that each extend between the front wall portion and the rear wall portion. The outer beam profile and the inner beam profile may be formed from a single sheet material through a roll-forming process. The inner beam profile may be present over a central section of the elongated hollow body and have a length that is less than half the length of the elongated hollow body.

Abstract: A reinforcement beam for a vehicle has an outer beam profile and a reinforcing insert introduced during the roll-forming process. The outer beam profile defines an elongated hollow body and includes a front wall portion and a rear wall portion. The outer beam profile may include upper and lower flanges formed in planar extension of the font wall portion. The reinforcing insert may define an upper shear wall and a lower shear wall that each extend between the front wall portion and the rear wall portion. The reinforcing insert may be introduced to a partial profile in a roll-forming process through an automated operation. The reinforcing insert may be present over a central section of the elongated hollow body and have a length that is less than half the length of the elongated hollow body.

Abstract: A reinforcement beam for a vehicle has an outer beam and an inner beam. The outer beam spans laterally between crush cans of the vehicle. The outer beam forms an elongated hollow body that has a front wall and a rear wall extending along the length of the reinforcement beam. The inner beam is disposed along an intermediate section of the outer beam. The inner beam further includes an upper wall and a lower wall that each extend between the front wall and the rear wall of the outer beam. The front wall and the rear wall may include at least one rib that extends along the length of the outer beam.

Abstract: A vehicle beam assembly includes a hollow tubular member configured to be formed with steel tube air forming. The tubular member includes a varied cross section along a length of the tubular member. For example, the hollow tubular member includes a center portion having a first cross-sectional shape, a pair of end portions that extend past corresponding crush cans in a direction away from the center portion, where the pair of end portions extend at an angle of 40-70 degrees, and at least one transition portion disposed between the center portion and one of the pair of end portions. A cross-sectional shape of the center portion, a cross sectional shape of one of the end portions, and a cross-sectional shape of the transition portion are all different cross-sectional shapes.

Abstract: A pultruded profile is provided that has fiber reinforcements longitudinally extending parallel relative to each other along the length of the pultruded profile. A tracer element is disposed longitudinally along one of fiber reinforcements. A resin is disposed over the fiber reinforcements and the tracer element to form a consistent cross-sectional shape continuously along a length of the pultruded profile. The tracer element is identifiable at a cut end of the pultruded profile to provide an indication of a location of the corresponding fiber reinforcement of the plurality of fiber reinforcements in the pultruded profile.