Abstract: A reinforcement beam for an automotive component includes a hollow beam structure formed from a metal sheet, such as a high-strength steel. The hollow beam structure has two adjacent tubular portions that share a common center wall and together extend along the length of the hollow beam structure. The two adjacent tubular portions may each have a first side wall and a second side wall arranged on opposing sides of the adjacent tubular portions. The two adjacent tubular portions are each closed with a weld seam that is formed between an edge portion of the metal sheet and an intermediate portion of the metal sheet. The edge portions interface in a perpendicular configuration with the respective interfacing intermediate portion of the metal sheet.

Abstract: A front rail configured to be supported by a vehicle frame includes a tubular body formed by a roll-formed high-strength metal and configured to undergo axial loading during a frontal vehicle impact. The high-strength metal steel defines a cross-sectional shape along a length of the tubular body. The tubular body includes a central wall extending from a first side wall to a second side wall defining at least a first longitudinal hollow channel and a second longitudinal hollow channel. A first crush initiator is disposed in the first side wall of the tubular body at a first crush area and is formed in the high-strength metal before roll-forming the tubular body. A second crush initiator is disposed in the corners of the tubular body at a second crush area and is formed in the high-strength metal after roll-forming the tubular body.

Abstract: A front rail configured to be supported by a vehicle frame includes a tubular body formed by a roll-formed high-strength metal and configured to undergo axial loading during a front vehicle impact. The high-strength metal sheet defines a cross-sectional shape along a length of the tubular body. The tubular body includes a central wall extending from a first side wall to a second side wall defining at least a first longitudinal channel and a second longitudinal channel. A groove is disposed in first side wall of the tubular body and extends longitudinally along at least a portion of the length of the tubular body to stiffen the tubular body. A hole extends through the first side wall of the tubular body proximate the groove and is configured as a bend initiator.

Abstract: A reinforcement beam for an automotive component is continuously formed with a metal sheet that is roll formed to have at least one tubular portion that extends along a length of the reinforcement beam. A solid state forge weld is formed between an edge of the metal sheet and an intermediate portion of the metal sheet to close a seam that extends along the tubular portion of the reinforcement beam. Prior to forming the solid state forge weld, select portions of the metal sheet are heated to a desirable welding temperature with a high frequency current delivered by electrical contacts to opposing sides of the weld seam. The desired welding temperature may burn off a galvanized coating on the metal sheet at the select portions prior to forming the solid state forge weld that is generally void of zinc inclusions.

Abstract: A battery tray for an electric vehicle includes a battery support structure that has a floor and a perimeter wall extending around a peripheral portion of the floor to border a battery containment area. A plurality of cross members are coupled with the perimeter wall at opposing sides of the battery support structure, where the cross members extend laterally across the battery containment area. A cover is engaged with an upper portion of the perimeter wall of the battery support structure. The cover, the floor, and/or the cross members may include a retention element that is integrally formed therewith and that is configured to engage a component that is disposed in the battery containment area.

Abstract: A battery tray for an electric vehicle includes a battery support structure that has a floor and a perimeter wall extending around a peripheral portion of the floor to border a battery containment area. A plurality of cross members are coupled with the perimeter wall at opposing sides of the battery support structure, where the cross members extend laterally across the battery containment area. A cover is engaged with an upper portion of the perimeter wall of the battery support structure. The cover, the floor, and/or the cross members may include a retention element that is integrally formed therewith and that is configured to engage a component that is disposed in the battery containment area.