Abstract: A vehicle beam component includes an elongated beam having a first wall, a second wall, and a third wall interconnecting the first and second walls to define a channel along a length of the elongated beam. The vehicle beam component also includes an array of stiffening members secured in the channel and disposed along the elongated beam in a spaced arrangement that is configured to stiffen the elongated beam from a laterally directed impact at a majority section of the length. Each stiffening member of the array of stiffening members extends between and is secured to the first and second walls of the elongated beam. Each stiffening member also includes a wall portion that is disposed orthogonal to the third wall of the elongated beam and transverse to the length of the beam, such that the wall portion is configured to axially absorb the laterally directed impact.

Abstract: A vehicle rocker assembly includes a sill outer and a sill inner that together define an elongated hollow interior. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior. The rocker insert includes a top wall, a bottom wall, a side wall coupled to and extending between the top wall and the bottom wall, with the top wall, the bottom wall, and the side wall at least partially defining a second hollow interior. The rocker insert also includes a stiffening member at least partially disposed within the second hollow interior and configured to be produced by extrusion, the stiffening member defining a plurality of enclosed sections extending along a length of the elongated hollow interior. Moreover, plurality of enclosed sections are configured to carry a load path laterally between the inboard and outboard wall portions.

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 vehicle rocker assembly includes one or more of a sill outer or a sill inner to define an elongated hollow interior. The vehicle rocker assembly also includes a stiffening member disposed within the hollow interior. The rocker insert includes a first stiffening member having a top wall, a bottom wall, and a side wall. The rocker insert also includes a second stiffening member including a plurality of wall sections that each include an upper portion engaged with the top wall and a lower portion engaged with the bottom wall at a location spaced along the length of the rocker insert from the upper portion. The top and bottom walls of the first stiffening member are configured to be supported by the second stiffening member when undergoing the inboard lateral impact force to increase lateral bending strength of the rocker insert.

Abstract: A vehicle rocker assembly includes a sill outer and a sill inner that together define an elongated hollow interior. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior. The rocker insert includes a stiffening member defining a wave-shaped structure and including at least one sheet defining a fore edge, an aft edge, a first side edge and a second side edge opposite the first side edge. Additionally, the fore edge and the aft edge are disposed at different locations along the length of the rocker insert. Moreover, a crest of the wave-shaped structure extends between the first side edge and the second side edge and is configured to carry a load path laterally between the inboard and outboard wall portions.

Abstract: A vehicle rocker assembly may include a sill inner comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly may also include a sill outer comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior, the rocker insert comprising: an upper wall, a lower wall, and a side wall extending between the upper wall and the lower wall. At least one of the upper wall or the lower wall comprises a corrugated portion that has a ridge oriented to extend in a lateral vehicle direction.

Abstract: A vehicle rocker assembly includes an outer sill member and an inner sill member attached longitudinally along the outer sill member to define a hollow space along and between the inner and outer sill members. A tubular insert is disposed in the hollow space so as to extend longitudinally along the hollow space. The tubular insert has a crush control feature extending longitudinally along a wall of the tubular insert, such as upper and lower walls at opposing sides of the interior volume. The tubular insert is configured for side impact forces at the outer sill member to laterally deform the tubular insert at the crush control feature to provide an accordion-style lateral crush to absorb the side impact forces.

Abstract: A vehicle rocker assembly includes a tubular insert disposed between a sill inner and a sill outer. The tubular insert may include an inboard wall disposed adjacent the sill inner, an outboard wall disposed adjacent the sill outer, an upper wall extending between upper ends of the inboard and outboard walls, a lower wall extending between lower ends of the inboard and outboard walls, and a center wall disposed between the upper and lower walls. The center wall may extend between the inboard and outboard walls with a length less than the upper and lower walls.

Abstract: A rocker component for a vehicle includes a tubular beam having a transverse cross-sectional shape extending continuously along a length of the tubular beam. The transverse cross-sectional shape of the tubular beam includes an inboard portion that has an inboard height dimension and an outboard portion that has an outboard height dimension. The outboard height dimension is less than the inboard height dimension. The transverse cross-sectional shape of the tubular beam also includes an upper planar wall and a lower planar wall that connect linearly between the respective upper and lower ends of the inboard portion and the outboard portion to form a tapered shape.

Abstract: A vehicle rocker assembly includes an outer sill member and an inner sill member attached longitudinally along the outer sill member to define a hollow space along and between the inner and outer sill members. A tubular insert is disposed in the hollow space so as to extend longitudinally along the hollow space. The tubular insert has a crush control feature extending longitudinally along a wall of the tubular insert, such as upper and lower walls at opposing sides of the interior volume. The tubular insert is configured for side impact forces at the outer sill member to laterally deform the tubular insert at the crush control feature to provide an accordion-style lateral crush to absorb the side impact forces.

Abstract: A battery tray for a vehicle includes a peripheral tubular member that borders at least a lateral side of a battery containment area relative to the vehicle. A crush section is attached along an outboard side of the peripheral tubular member. The crush section includes an outboard wall portion, an upper leg portion integrally extending inboard from an upper end of the outboard wall potion, and a lower leg portion integrally extending inboard from a lower end of the outboard wall potion. The upper and lower leg portions of the crush section each terminate inboard at an end flange of the crush section that is attached to the peripheral tubular member to enclose a hollow interior there between.

Abstract: A crossmember for a vehicle battery tray provides a beam that has a closed cross-sectional shape with a top wall coupled with parallel side walls along a length of the beam. A reinforcing top cap is disposed along the beam, where a C-shaped transverse cross-sectional shape of the top cap has a central section that disposed along the top wall and legs of the top cap welded to the side walls. The legs include inward angled tabs that are biased against the beam and welded thereto. The top wall of the beam and the central section of the top cap have aligned fastener openings disposed at spaced intervals along the length of the beam and configured to receive fasteners that secure at least one of a battery module or tray cover to the crossmember.

Abstract: A crossmember for a vehicle battery tray provides a beam that has a closed cross-sectional shape with a top wall coupled with parallel side walls along a length of the beam. A reinforcing top cap is disposed along the beam, where a C-shaped transverse cross-sectional shape of the top cap has a central section that disposed along the top wall and legs of the top cap welded to the side walls. The legs include inward angled tabs that are biased against the beam and welded thereto. The top wall of the beam and the central section of the top cap have aligned fastener openings disposed at spaced intervals along the length of the beam and configured to receive fasteners that secure at least one of a battery module or tray cover to the crossmember.