Title of the invention

Abstract

The vehicle rocker panel comprises an outer plate, an inner plate, and a reinforcing structure. The reinforcing structure is positioned between the inner plate and the outer plate. The reinforcing structure includes one or more individual steel pipes that extend longitudinally between the outer plate and the inner plate.

Description

Technical Field

[0001] This application claims priority to U.S. Provisional Application No. 63 / 466,477, titled "Steel Pipe as a Reinforcement for Vehicle Structures," filed on May 15, 2023, the disclosure of which is incorporated herein by reference.

Background Art

[0002] The present invention relates to the structural reinforcement of one or more components used in a vehicle. Vehicles use various structural components to protect both passengers and internal mechanical and electrical systems. In the event of a collision, these structural components may be configured to absorb energy and / or deform in a more controlled and predictable manner. The reinforcement structures used in combination with these structural components can contribute to the ability of these structural components to absorb energy and / or deform in a more controlled and predictable manner.

[0003] One such structural component is, for example, a rocker panel. In a vehicle, one or more rocker panels may extend near the bottom of the vehicle, under the passenger door, and between the front and rear wheels. Depending on the rocker panel, it may be desirable to provide a structural reinforcement. For example, an electric vehicle or an internal combustion engine hybrid vehicle may be equipped with a battery or a battery array. Such a battery may be located near the rocker panel and may extend along the bottom of the vehicle. In such a situation, it may be desirable to provide such a reinforcement to protect the battery from a side collision.

[0004] Examples of various reinforcement structures include U.S. Patent Publication No. 2023 / 0016200 for the invention titled "Rocker Component with Tapered Shape," published on January 19, 2023; U.S. Patent Publication No. 2022 / 0289298 for the invention titled "Multi-Beam Side Frame Assembly," published on September 15, 2022; U.S. Patent No. 11,524,645 for the invention titled "Beam Assembly with Multi-Hollow Formation," issued on December 13, 2022; U.S. Patent Publication No. 2022 / 0063728 for the invention titled "Rocker Assembly Insert with Opposed Crush Channels," published on March 3, 2022; U.S. Patent No. 8,960,781 for the invention titled "Single Piece Vehicle Rocker Panel," issued on February 24, 2015; and the invention titled "Reinforcement" published on January 12, 2023. This is disclosed in U.S. Patent Application No. 2023 / 0008826, “for a Side-Impact,” and in U.S. Patent No. 10,483,510, “Polarized Battery Tray for a Vehicle,” issued on November 19, 2019. The disclosures of the aforementioned U.S. patents and publications are incorporated herein by reference. [Brief explanation of the drawing]

[0005] [Figure 1] Figure 1 is a perspective view of an example vehicle. [Figure 2] Figure 2 is a partial perspective view of an example of a reinforced rocker panel that can be incorporated into the vehicle shown in Figure 1. [Figure 3] Figure 3 is a front cross-sectional view of the reinforcing rocker panel shown in Figure 2, with the cross-section taken along line 3-3 in Figure 2. [Figure 4] Figure 4 shows a front cross-sectional view of another example of a reinforced rocker panel that can be easily incorporated into the vehicle shown in Figure 1. [Figure 5]Figure 5 shows a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle shown in Figure 1. [Figure 6] Figure 6 shows a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle shown in Figure 1. [Figure 7] Figure 7 shows a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle of Figure 1. [Figure 8] Figure 8 shows a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle shown in Figure 1. [Figure 9] Figure 9 is a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle of Figure 1. [Figure 10] Figure 10 shows a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle of Figure 1. [Figure 11] Figure 11 is a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle of Figure 1. [Figure 12] Figure 12 is a front cross-sectional view of yet another example of a reinforced rocker panel that can be easily incorporated into the vehicle of Figure 1. [Figure 13] Figure 13 shows a front view of the rocker reinforcement that will be subjected to mechanical testing. [Figure 14] Figure 14 shows a front view of the comparative rocker reinforcement material that will be subjected to mechanical testing. [Figure 15] Figure 15 is a graph comparing experimentally obtained force-displacement data from a three-point bending test of the rocker reinforcement configuration shown in Figure 13 with force-displacement data obtained from finite element analysis (FEA). [Figure 16] Figure 16 is a graph of force-effective energy absorption and displacement data derived from FEA for the rocker reinforcement configuration shown in Figure 13, scaled to 1500-grade steel. It is compared with experimentally derived data for the aluminum rocker reinforcement configuration shown in Figure 14. [Figure 17]Figure 17 shows plots of force-effective energy absorption and displacement data derived from the FEA of rocker reinforcements scaled to three different thicknesses using 1500-grade steel, as well as data derived from experiments with aluminum rocker reinforcements in the comparative rocker panel configuration shown in Figure 14. [Figure 18] Figure 18 shows a front view of another rocker reinforcement that will be subjected to mechanical testing. [Figure 19] Figure 19 shows a comparison between the experimentally obtained graphs of force-effective energy absorption and displacement data for the rocker reinforcement material in Figure 18 and the experimentally obtained data for the aluminum rocker reinforcement material in the comparative rocker panel configuration in Figure 14. [Modes for carrying out the invention]

[0006] Various vehicle structures may be suitable for one or more reinforcement configurations. While this specification uses rocker panel reinforcement as an example, it should be understood that the reinforcement configurations described herein can be easily used as various alternative load-bearing vehicle structures or in combination with them. Suitable alternative structures include, for example, posts such as A-posts, B-posts, C-posts, and D-posts, bumpers, roof bows, roof rails, dash panels, cross members, and window rails. Furthermore, while this specification uses side impact mitigation to protect components such as batteries as an example, it should be understood that the reinforcement configurations described herein can be easily used to protect other vehicle components or areas. For example, the reinforcement configurations described herein can be used to protect motors, engines, electrical components, passenger compartments, storage compartments, etc.

[0007] Figure 1 shows an example of a vehicle (10) with wheels (12) and multiple doors (14). While the vehicle (10) in this example is shown in a specific configuration (e.g., a four-door compact car), it should be understood that various alternative configurations of the vehicle (10) are available in other examples. Generally, passengers can enter and exit the vehicle (10) through one or more doors (14), and the wheels (12) are used to propel the vehicle (10). Although not shown, it should be understood that the vehicle (10) may have a powertrain configured to drive the wheels (12). Suitable powertrains include electric motors, internal combustion engines, or a combination thereof. One or more batteries can be housed within the vehicle (10) to transmit power between the motors, engines, and / or various auxiliary components, as will be described in more detail below.

[0008] The vehicle (10) further comprises a rocker panel (50) extending between the wheels (12) and below one or more doors (14). In this example, the rocker panel (50) is shown as a single panel extending from one wheel (12) to the other wheel (12). In other examples, the rocker panel (50) may be formed as an assembly of multiple interconnected rocker panels (50). Although not shown, it should be understood that the vehicle (10) may have rocker panels (50) on both sides of the vehicle (10) (e.g., the right and left sides). Furthermore, although the rocker panel (50) in this example is generally located below one or more doors (14), it should be understood that in some examples, at least a portion of the rocker panel (50) may extend upward relative to one or more doors (14) below at least a portion of one or more doors (14). In other words, in some examples, the rocker panel (50) and one or more doors (14) may overlap at least to some extent.

[0009] The rocker panel (50) is generally configured to extend from the front to the rear of the vehicle (10) to provide structural rigidity to the vehicle (10). The structural rigidity provided by the rocker panel (50) can be achieved by various dimensions. For example, rigidity can be achieved by resisting various tensile loads resulting from the parts of the vehicle (10), the movement of the vehicle (10), or collisions with the vehicle (10). Similarly, rigidity can be achieved by resisting various compressive loads resulting from the parts of the vehicle (10), the movement of the vehicle (10), or collisions with the vehicle (10). The rocker panel (50) is also generally configured to provide structural integrity to the vehicle (10) by connecting the front of the vehicle (10) to the rear of the vehicle (10).

[0010] The rocker panel (50) of this embodiment further comprises a specific reinforcing structure configured to withstand side impacts. As best shown in Figure 2, the rocker panel (50) of this embodiment comprises a reinforcing structure (60) positioned between an outer plate (52) and an inner plate (56). The outer plate (52) and the inner plate (56) each comprise tapered portions (54, 58). Each tapered portion (54, 58) extends outward from a portion of the outer plate (52) and the inner plate (56), respectively. This outward taper is generally configured to accommodate the structure of the reinforcing structure (60) between the outer plate (52) and the inner plate (56). While the tapered portions (54, 58) of this embodiment are generally angular in shape, it should be understood that in other embodiments, the tapered portions (54, 58) may be curved or spherical in shape.

[0011] As best illustrated in Figures 2 and 3, the reinforcing structure (60) includes a plurality of tubes (62) arranged to extend from the outer plate (52) to the inner plate (56). The tubes (62) are generally configured to provide structural reinforcement to the rocker panel (50). Specifically, the tubes (62) are configured to provide both energy absorption and intrusion prevention. In other words, the tubes (62) are configured to deform in a predetermined manner to absorb impact energy and prevent any part of the rocker panel (50) from penetrating into a predetermined enclosure.

[0012] While the pipe (62) in this example is shown in a specific configuration, it should be understood that the pipe (62) can take on various alternative configurations. Such alternative configurations may be desirable to provide scalability to meet target performance and flexibility to conform to target product design requirements. For example, scalability can be provided by using different material grades, gauges, and joining methods for the pipe (62). Similarly, flexibility can be provided by using different orientations or layouts for the pipe (62). Some suitable alternative configurations for the pipe (62) will be described in more detail below, but other alternative configurations for the pipe (62) will be obvious to those skilled in the art in light of the teachings herein.

[0013] In this example, the tube (62) is positioned between the outer plate (52) and the inner plate (56) in the space defined by the tapered sections (54, 58). The tube (62) also extends longitudinally between the outer plate (52) and the inner plate (56) along the length of the rocker panel (50), although in other examples, the tube (62) may be separated into one or more sections of the rocker panel (50). This example includes three tubes (62) aligned along a single axis extending laterally from the outer plate (52) to the inner plate (56). In other words, one row of tubes (62) is positioned from one side of the rocker panel (50) to the other.

[0014] The tube (62) in this example has a specific configuration or orientation relative to each other, but it should be understood that in other examples, the orientation of the tube (62) can be changed. Such a change in the orientation of the tube (62) may be desirable to enhance the flexibility to conform the performance of the reinforcement structure (60) to the targeted performance criteria. As will be explained in more detail below, suitable alternative orientations and configurations include, for example, an additional row of tubes (62) or a reduced row of tubes (62). Additionally, or alternatively, in some examples, the tubes (62) may be arranged in a grid or array having multiple rows of tubes (62). In still other examples, some of the tubes (62) may be arranged in a grid or array, while other tubes (62) may be arranged in rows. Other suitable configurations or orientations of the tubes (62) will be apparent to those skilled in the art in view of the teachings of this specification.

[0015] Each tube (62) in this example defines a square or box-shaped cross-section. Such a square or box-shaped shape may be desirable from the viewpoints of ease of manufacture and availability of materials. In other examples, the tubes (62) can define various alternative shapes. For example, in some examples, each tube (62) may be cylindrical, rectangular, triangular, D-shaped, etc. In still other examples, a non-tubular structure such as an I-shaped structure may be used. In still other examples, one or more of the tubes (62) may be made of a different shape than the other tubes (62), and various combinations of the above shapes may be provided.

[0016] Each tube (62) in this example also defines a specific gauge or wall thickness. The wall thickness in this example is approximately 1.2 mm. In other examples, various alternative gauges or wall thicknesses can be used. For example, in some examples, the wall thickness of each tube (62) is 1.2 mm to 1.8 mm. In still other examples, the wall thickness of each tube (62) is 1.0 mm to 2.0 mm. In still other examples, the wall thickness of each tube is 1.0 mm to 3.6 mm. In still other examples, various alternative gauges or wall thicknesses are available, as would be apparent to those skilled in the art in view of the teachings herein. In such examples, the appropriate wall thickness may be related to the material used for each tube (62) in order to achieve certain performance criteria such as energy absorption strength and / or toughness. Thus, a tube (62) made of a superior material may have a lower gauge or wall thickness because of the higher strength or toughness of the superior material, and vice versa.

[0017] Each tube (62) is generally composed of steel. The specific grade used for the steel can correspond to desired performance criteria such as energy absorption and / or intrusion protection. In this example, the steel is dual-phase 780 grade (DP780). In other examples, various alternative grades can be used. For example, in other examples, the steel can be 1500 grade (e.g., ULTRALUME® 1500 manufactured by Cleveland-Cliffs, Inc.). In still other examples, the steel can include mild steel grades, high-strength steel grades, advanced high-strength steel grades, and / or ultra-high-strength steel grades from 1650 MPa to 2000 MPa. Additionally, or alternatively, in some examples, each tube (62) can be a tailor-welded configuration having one or more combinations of different steel grades and thicknesses within a single tube (62). Such different thicknesses and grades can be applied to different configurations of the wall of the tube (62), such as the front, back, sides, etc. As described above, in some examples, the specific grade of steel used may have a predetermined relationship with the gauge or wall thickness of each tube (62). Thus, in examples where the grade or wall thickness of each tube (62) is limited, there may also be corresponding limitations on the wall thickness or grade of each tube (62).

[0018] Each pipe (62) is typically fixed or fastened to an adjacent pipe (62). In this example, each pipe (62) is joined to an adjacent pipe (62) by laser welding. In other examples, various alternative joining methods may be used. For example, in some examples, pipes (62) may be joined by other welding methods such as arc welding, resistance welding, or solid welding. In yet another example, pipes (62) may be joined by mechanical fastening systems using various fasteners or combinations thereof, such as bolts, fasteners, collars, and clamps. In yet another example, pipes (62) may be joined by chemical fastening methods such as adhesives. Of course, any such joining method described herein can be combined with other such joining methods to join pipes (62) using a combination of multiple joining methods. It should be understood that similar joining methods may be used to join pipes (62) to the outer plate (52) and / or inner plate (56).

[0019] As described above, the pipes (62) can be arranged relative to each other in various orientations or configurations. Figures 4-12 show alternative reinforcing structures (70, 80, 90, 210, 220, 230, 240, 250, 260) that can be easily incorporated into the rocker panel (50) in addition to or instead of the reinforcing structure (60) described above. Similar to the reinforcing structure (60) described above, each alternative reinforcing structure (70, 80, 90, 210, 220, 230, 240, 250, 260) includes one or more pipes (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) that can add structural reinforcement to the rocker panel (50).

[0020] Although the pipes (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) are shown as being similar to pipe (62) above, it should be understood that each pipe (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) can similarly consist of various shapes, gauges or wall thicknesses, and / or materials. For example, similar to the pipe (62) described above, the alternative pipes (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) can have various alternative shapes or combinations of shapes, such as cylindrical, rectangular, triangular, and D-shaped. Similarly, the gauge or wall thickness of each pipe (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) may vary between approximately 1 mm and approximately 2 mm. The material of each pipe (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) is also steel, and various grades or combinations of multiple grades of steel are used. The pipes (72, 82, 92, 212, 214, 222, 224, 232, 242, 244, 252, 254, 256, 262, 266) can also be joined to adjacent structures by various joining techniques such as welding, brazing, mechanical fastening, and / or chemical fastening.

[0021] Figure 4 shows an alternative reinforcing structure (70) including tubes (72) in a grid or matrix configuration. As shown, five tubes (72) are arranged in a continuous configuration extending between the outer plate (52) and the inner plate (56). Specifically, in this example, the configuration of tubes (72) includes four 4x4 grid tubes (72) and one tube (72) adjacent to the 4x4 grid tubes (72). All tubes (72) are arranged generally symmetrically along a common transverse axis extending perpendicular to the outer plate (52) and the inner plate (56).

[0022] Furthermore, the combination of 4x4 grid tubes (72) and single tubes (72) results in an asymmetrical overall configuration of the tubes (72), with more tubes on one side of the rocker panel (50) (e.g., the outboard plate (52) side) than on the other side. This asymmetrical configuration may be desirable for controlling the energy absorption or strain characteristics of the reinforcing structure (70). For example, tubes (72) configured as a 4x4 grid can be configured to absorb more energy compared to single tubes (72). Therefore, 4x4 grid tubes (72) can be positioned closer to the expected impact area (e.g., the outboard plate (52)).

[0023] Figure 5 shows another alternative reinforcing structure (80) which includes tubes (82) in a different column configuration similar to the one described above with respect to tubes (62). In this example, the reinforcing structure (80) includes two tubes (82) arranged in a continuous manner along a common transverse axis that extends perpendicular to the outer plate (52) and the inner plate (56).

[0024] Since the same distance can be covered by only two pipes (82), just like the pipe (62) described above, the cross-sectional shape of each pipe (82) can be changed accordingly. For example, each pipe (82) in this example has a roughly rectangular shape, and the elongated part of the rectangle is parallel to a common horizontal axis that extends perpendicularly to the outer plate (52) and the inner plate (56). Of course, in other examples, the pipes (82) may have a square shape, but their dimensions will be larger to accommodate the increased overall length.

[0025] Figure 6 shows yet another alternative reinforcing structure (90) including a single pipe (92). In this example, pipe (92) defines a roughly rectangular cross-sectional shape. Since pipe (92) can extend the same distance as pipe (62) described above with only a single pipe (92), the cross-sectional shape of pipe (92) is elongated to extend the same distance. Thus, pipe (92) defines a rectangle, and the elongated portion of the rectangle is parallel to a horizontal axis that extends perpendicular to the outer plate (52) and the inner plate (56). In this example, pipe (92) defines a rectangular shape, but it should be understood that in other examples, pipe (92) can be made into a square by increasing the dimensions of pipe (92) so that it can extend from the outer plate (52) to the inner plate (56).

[0026] Figure 7 shows yet another alternative reinforcing structure (210) including three tubes (212, 214). The tubes (212, 214) in this example include a pair of longitudinal tubes (212) and a single transverse tube (214), forming a generally asymmetrical configuration. The longitudinal tubes (212) are positioned between plates (52, 56) and extend from one side of the rocker panel (50) in a generally parallel or stacked configuration over a longer distance than the transverse tubes (214). In other words, the longitudinal tubes (212) are configured to occupy a wider width within the rocker panel (50) compared to the transverse tubes (214). In some examples, this configuration may be desirable to allow other structures of the vehicle (10) to pass through the tubes (212, 214) without adversely affecting performance. Furthermore, this configuration may be desirable to control performance characteristics depending on the side of the rocker panel (50) (e.g., comparing external and internal shock absorption).

[0027] All tubes (212, 214) define a generally rectangular cross-sectional shape, however, one or more of the tubes (212, 214) may have a different shape. Furthermore, at least some of the dimensions of the tubes (212, 214) may define a predetermined relationship with the other tubes (212, 214). For example, the longitudinal dimension of a laterally oriented tube (214) defines the length corresponding to the lateral dimension when two longitudinally oriented tubes (212) are stacked. Thus, the combination of tubes (212, 214) defines a generally rectangular shape. Therefore, the rectangular shape defined by the tubes (212, 214) is oriented such that the elongated portion of the rectangle is parallel to a transverse axis that extends perpendicular to the outer plate (52) and the inner plate (56). In this example, the tubes (212, 214) together define a rectangular configuration, but it should be understood that in other examples, the tubes (212, 214) can form other suitable shapes, including both regular and irregular shapes.

[0028] Figure 8 shows yet another alternative pipe reinforcement structure (220) including four pipes (222, 224). In this example, the pipes (222, 224) include a pair of transverse pipes (222) and a pair of longitudinal pipes (224). Generally, the transverse pipes (222) are wider from plate (52) to plate (56) than the longitudinal pipes (224). Thus, the pipes (222, 224) generally define an asymmetrical configuration over at least one dimension. As described above with respect to pipes (212, 214), such a configuration may be desirable to ensure clearance with other structures of the vehicle (10) or to further control performance characteristics.

[0029] While all pipes (222, 224) generally have a rectangular cross-sectional shape, in other examples, one or more of the pipes (222, 224) may have different shapes. Although all pipes (222, 224) generally have a rectangular shape, the size of one or more pipes (222, 224) may differ over a certain dimension. For example, in this example, the lateral dimension of one lateral pipe (222) is larger than that of the other lateral pipe (222), resulting in a longer distance between plates (52, 56) for one lateral pipe (222) than for the other lateral pipe (222). In this example, the lateral pipes (222) have different dimensions, but in other examples, the lateral pipes (222) may be identical.

[0030] In this example, the tubes (222, 224) are arranged in a specific pattern. For example, the laterally oriented tubes (222) are stacked in parallel along an axis extending from plate (52) to plate (56). Meanwhile, the longitudinally oriented tubes (224) are stacked in a height direction perpendicular to the arrangement of the laterally oriented tubes (222). In this configuration, the combination of longitudinally oriented tubes (224) determines a height that is approximately equal to or less than the longitudinal length of each laterally oriented tube (222). Therefore, the combined shape of all the tubes (222, 224) is approximately rectangular.

[0031] Figure 9 shows yet another alternative pipe reinforcement structure (230) including four pipes (232). The pipes (232) in this example are substantially identical and are arranged in a grid or matrix pattern in a 2x2 configuration from one plate (52) to the other plate (56). Each pipe (232) has a generally rectangular cross-sectional shape. The lateral dimensions of each pipe (232) are generally the same.

[0032] In some examples, the pipes (232) may have different longitudinal lengths. For example, in this example, a pair of pipes (232) on one side of the arrangement are longer in the longitudinal direction than the pipes (232) on the opposite side of the arrangement. Thus, in some examples, the pipes (232) may be arranged in an asymmetric configuration where the interface between the pipes (232) is closer to the other plate (52, 56) than to the other plate (52, 56). As described above, such an asymmetric configuration may be desirable to ensure clearance with other structures of the vehicle (10) or to further control performance characteristics.

[0033] Figure 10 shows yet another alternative reinforcing structure (240) including tubes (242, 244) in a grid or matrix configuration. As shown in the figure, five tubes (242, 244) are included in a continuous configuration extending between the outer plate (52) and the inner plate (56). Specifically, in this example, the configuration of tubes (242, 244) includes four roughly square tubes (242) arranged in a 4x4 grid, and one rectangular tube (244) adjacent to the 4x4 grid of these square tubes (242). All tubes (242, 244) are arranged approximately symmetrically along a common transverse axis extending perpendicular to the outer plate (52) and the inner plate (56).

[0034] Furthermore, the combination of 4x4 grid square tubes (242) and single rectangular tubes (244) results in an asymmetrical overall configuration of the tubes (242, 244), with more tubes positioned on one side of the rocker panel (50) (e.g., the outboard plate (52) side) than on the other side. Similarly, as mentioned above, this asymmetrical configuration may be desirable to ensure clearance with other components related to the vehicle (10) and / or to control the energy absorption or strain characteristics of the reinforcing structure (240). For example, square tubes (242) configured as a 4x4 grid can be configured to absorb more energy compared to single square tubes (242). Therefore, the 4x4 grid tubes (242) can be positioned closer to the expected impact area (e.g., the outboard plate (52)).

[0035] Figure 11 shows yet another alternative reinforcing structure (250) including linearly arranged tubes (252, 254, 256). As shown in the figure, the four tubes (252, 254, 256) are arranged in a continuous straight line extending between the outer plate (52) and the inner plate (56). Specifically, in this example, the tubes (252, 254, 256) include two roughly square tubes (252) stacked vertically, one trapezoidal tube (254) adjacent to both square tubes (252), and one rectangular tube (256) adjacent to the square tubes (252) on the opposite side of the trapezoidal tube (254). All tubes (252, 254, 256) are aligned almost symmetrically along a common transverse axis extending perpendicular to the outer plate (52) and the inner plate (56).

[0036] Furthermore, the combination of square tubes (252), trapezoidal tubes (254), and single rectangular tubes (256) results in an overall configuration of the tubes (252, 254, 256) that is asymmetrical from one side to the other of the rocker panel (50). Specifically, by stacking the square tubes (252), more structural material is positioned toward one side of the rocker panel (50). Similarly, as described above, this asymmetrical configuration may be desirable to ensure clearance with other components related to the vehicle (10) and / or to control the energy absorption or strain characteristics of the reinforcing structure (250). For example, by configuring the square tubes (252) in a bag-like manner, they can be configured to absorb more energy compared to a single square tube (252). Thus, the stacked tubes (252) can be positioned closer to the expected impact area (e.g., the outer plate (52)).

[0037] The combination of tubes (252, 254, 256) defines an overall tapered shape from one side to the other of the plate (52, 56). In particular, the stacked configuration of square tubes (252) defines a relatively high height, while the rectangular tubes (256) define a relatively low height. On the other hand, the trapezoidal tube (254) is placed between the square tubes (252) and the rectangular tubes (256), forming a taper from the height of the square tubes (252) to the height of the rectangular tubes (256). Thus, one side of the trapezoidal tube (254) is approximately the same height as the combination of square tubes (252), and the opposite side of the trapezoidal tube (254) is approximately the same height as the rectangular tubes (256). Such a configuration may be desirable in some cases in order to evenly distribute the force from the square tubes (252) to the rectangular tubes (256).

[0038] Figure 12 shows yet another alternative reinforcing structure (260) including tubes (262, 266) arranged in the internal tube configuration. Specifically, the reinforcing structure (260) includes an outer tube (262), an inner tube (266), and one or more webs (266) connecting the outer tube (262) and the inner tube (266). The outer tube (262) defines a roughly bow-tie shaped cross section, having wide sections adjacent to each plate (52, 56) and narrow sections positioned between the plates (52, 56). Optionally, in some examples, the narrow sections of the outer tube (262) may be positioned in the center between the plates (52, 56). In other examples, the narrow sections may be offset or deflected toward certain plates (52, 56). Alternatively, in other examples, the outer tube (262) may omit the narrow sections entirely and define a different cross-sectional shape. For example, in some cases, the outer tube (264) can be defined as having a roughly rectangular cross-sectional shape or an irregular shape.

[0039] The inner tube (266) is positioned within the outer tube (262) and extends longitudinally from one side of the outer tube (262) to the other. The inner tube (266) defines a substantially rectangular cross-sectional shape, having longitudinal dimensions defined by the distance between each wide section of the outer tube (262) and lateral dimensions defined by the space defined by the narrow sections of the outer tube (262). Although the inner tube (266) in this example is substantially rectangular, different cross-sectional shapes may be used in other examples. This example includes a single inner tube (266), but it should be understood that multiple inner tubes (266) may be used in other examples. In such examples, these multiple inner tubes (266) may be stacked horizontally or vertically. In addition, or alternatively, in some examples, additional tubes may be included within the inner tube (266) to define an inner-tube-inner-tube configuration.

[0040] If necessary, the reinforcing structure (260) includes a web (264) connecting the outer tube (262) and the inner tube (266). For example, in this example, the web (264) extends inward from the narrow section of the outer tube (262) that connects the inner tube (266) to the outer tube (262). Thus, in this example, the outer tube (262) and the inner tube (266) are largely integrated via the web (264). In other examples, the web (262) may be omitted. In such examples, the narrow section of the outer tube (262) may directly intersect the inner tube (266). Alternatively, in some examples, there may be no structure with respect to the narrow section of the outer tube (262) that connects the narrow section of the outer tube (262) to the inner tube (266). [Examples]

[0041] The first test sample (160) was fabricated according to the description of the reinforcement structure (60) above. Specifically, Figure 13 shows the first test sample (160) in which three pipes (162) are joined to form a pipe row (162), with each pipe (162) arranged in a single line along a common axis. Each pipe (162) was fabricated with a roughly square cross-sectional shape, with one side measuring 27 mm and the other side measuring 30 mm. All pipes (162) were made of DP780 grade steel. The gauge thickness or wall thickness of each pipe (162) was 1.2 mm. The pipes were joined by laser welding.

[0042] The first test sample (160) was subjected to a three-point bending test with a force (F) applied to it, as shown in Figure 13. In the three-point bending test, an anvil diameter of 100 mm, a punch travel of 100 mm, and a support span of 400 mm were used.

[0043] A finite element analysis (FEA) model was also created for the first test sample (160), and the same three-point bending test was performed using digital simulation. As shown in Figure 15, the results of the experimental three-point bending test and the FEA digital simulation were compared. A good correlation was observed between the experimental three-point bending test and the digital simulation. [Examples]

[0044] As a comparative example, a second test sample (180) was prepared. Specifically, Figure 14 shows the second test sample (180), which includes a single, integrated component defining a body (182) and webs (184) extending from both sides of the body (182). The webs (184) were positioned in the center of each side. The body (182) had a rectangular cross-section with a long side length of 88 mm and a short side length of 50 mm. The length of the webs (184) was 40.8 mm (the length of the short side minus the wall thickness). The wall thickness of both the body (182) and the webs (184) was 4.6 mm. The second test sample (180) was constructed to have substantially the same weight as the first test sample (160). Specifically, the first test sample (160) has a low material content but high density (e.g., steel), while the second test sample (180) has a high material content but low density (e.g., aluminum).

[0045] As described above, the second test sample (180) was molded as a single part. To mold the second test sample (180) as a single part, it was extruded using aluminum material. The aluminum material used was 6000 series aluminum.

[0046] The second test sample (180) was subjected to a three-point bending test with a force (F) applied to it, as shown in Figure 14. In the three-point bending test, an anvil diameter of 100 mm, a punch travel of 100 mm, and a support span of 400 mm were used.

[0047] The FEA model validated in the test of Example 1 was scaled down to 1500 MPa class steel with a gauge thickness or wall thickness of 1.7 mm (specifically, ULTRALUME® 1500 from Cleveland-Cliffs). The same three-point bending test was digitally simulated again using the scaled FEA model. As shown in Figure 16, the results of the experimental three-point bending test of the second test sample (180) were compared with the results of the FEA digital simulation of the scaled FEA model. In both peak force and energy absorption, the scaled FEA model showed superior performance to the second test sample (180). Therefore, a rocker panel with a reinforcing structure of the configuration of the first test sample (160) made of 1500 MPa class steel shows superior performance to the second test sample (180) made of aluminum, even though both configurations are substantially the same weight. [Examples]

[0048] Further digital simulations were performed to test the relationship between pipe thickness and performance for the configuration of the first test sample (160). Similar to Example 2 described above, the test in Example 1 was scaled up to 1500 MPa class steel (specifically, ULTRALUME® 1500 from Cleveland-Cliffs). The same three-point bending test was again digitally simulated using the scaled-up FEA model. However, unlike the simulation in Example 2 described above, this simulation was performed with various pipe (162) thicknesses. Specifically, thicknesses of 1.4 mm, 1.7 mm, and 1.9 mm were simulated. A thickness of 1.4 mm corresponds to a steel configuration with 15% less mass compared to the aluminum configuration of the second test sample (180). A thickness of 1.7 mm corresponds to a steel configuration with approximately the same mass as the aluminum configuration of the second test sample (180). A thickness of 1.9 mm corresponds to a steel configuration with a 15% increase in mass compared to the aluminum configuration of the second test sample (180).

[0049] The results of the experimental three-point bending test of the second test sample (180) were compared with the results of FEA digital simulations using scale FEA models with thicknesses of 1.4 mm, 1.7 mm, and 1.9 mm. The scale FEA models at different thicknesses showed superior performance to the second test sample (180) in both peak force and energy absorption. While no superior performance was observed compared to the 1.4 mm thick model in terms of peak force, superior performance was still observed in terms of energy absorption after a displacement of approximately 55 mm compared to the aluminum second test sample (180). Therefore, a rocker panel with a reinforced structure in the configuration of the first test sample (160), made of 1500 MPa class steel, shows superior performance to the second test sample (180), made of aluminum, despite both configurations being substantially the same weight. Furthermore, the rocker panel with a reinforced structure in the configuration of the first test sample (160), made of 1500 MPa class steel, is lighter than the configuration of the first test sample (160), while being superior to the second test sample (180), made of aluminum, at least in some capacity. [Examples]

[0050] The third test sample (190) was prepared according to the description of the reinforcement structure (60) above. Specifically, Figure 18 shows the third test sample (190) in which three tubes (192) were joined to form a tube (192) in which each tube (192) was arranged in a row (or column, depending on the orientation) along a common axis. Each tube (192) was prepared to have a roughly square cross-section with one side measuring 27 mm and the other side measuring 30 mm. All tubes (192) were made of 1500 MPa class steel (specifically, FORMTUBE® QHS 1500 manufactured by Cleveland Cliffs Corporation). The gauge thickness or wall thickness of each tube (192) was 1.8 mm. The tubes were joined by laser welding.

[0051] As shown in Figure 18, a three-point bending test was performed on the third test sample (190) by applying a force (F). In the three-point bending test, the anvil diameter was 100 mm, the punch travel was 100 mm, and the support span was 400 mm.

[0052] Figure 19 shows the results of the experimental three-point bending test of the third test sample (190). For comparison, Figure 19 also shows the results of the experimental three-point bending test of the second test sample (180) described above for Example 2. The third test sample (190) showed superior performance to the second test sample (180) in both peak force and energy absorption. Therefore, the rocker panel with the reinforced structure of the third test sample (190), made of 1500 MPa class steel, showed superior performance to the second test sample (180), made of aluminum, despite both configurations being of almost the same weight. More specifically, the third test sample (190) showed significantly superior performance in peak force (33% performance improvement) and energy absorption (over 50% performance improvement) despite being 10% heavier than the second test sample (180). [Examples]

[0053] A rocker panel used in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, the reinforcing structure including one or more individual steel pipes extending longitudinally between the outer plate and the inner plate, A rocker panel having the following features. [Examples]

[0054] A rocker panel according to Example 5, wherein the reinforcing structure includes three tubes arranged along an axis extending from the outer plate to the inner plate. [Examples]

[0055] In the rocker panel described in Example 6, the pipes are arranged in a single row. [Examples]

[0056] A rocker panel according to Example 5, wherein the reinforcing structure includes five tubes, and one or more of the tubes are arranged to extend continuously from the outer plate to the inner plate. [Examples]

[0057] A rocker panel according to Example 8, wherein four of the five pipes are arranged in a 4x4 grid pattern, and one of the five pipes is arranged adjacent to the 4x4 grid pattern. [Examples]

[0058] A rocker panel according to Example 8 or 9, wherein the tubes are arranged symmetrically along a common axis extending from the outer plate to the inner plate. [Examples]

[0059] A rocker panel according to Example 10, wherein the common axis is oriented perpendicularly to a portion of the outer plate and a portion of the inner plate. [Examples]

[0060] A rocker panel according to Example 5, wherein the reinforcing structure includes two tubes, the two tubes being arranged to extend continuously from the outer plate to the inner plate. [Examples]

[0061] A rocker panel according to Example 12, wherein the two tubes form a row extending from the outer plate to the inner plate. [Examples]

[0062] A rocker panel according to Example 6, wherein the reinforcing structure includes a single tube extending from the surface of the outer plate to the surface of the inner plate. [Examples]

[0063] A rocker panel according to any of Examples 5 to 14, wherein each of the one or more pipes defines a square cross-section. [Examples]

[0064] A rocker panel according to any of Examples 5 to 14, wherein each of the one or more pipes defines a circular cross-section. [Examples]

[0065] A rocker panel according to any one of claims 5 to 16, wherein each of the one or more pipes has a defined wall thickness, and this wall thickness is 1 to 2 mm. [Examples]

[0066] A rocker panel according to Example 17, wherein the wall thickness is 1.2 mm or 1.8 mm. [Examples]

[0067] A rocker panel according to any of Examples 5 to 18, wherein each of the one or more tubes is made of a single-grade steel, and this single-grade steel includes two-phase 780 grade steel. [Examples]

[0068] A rocker panel according to any of Examples 5 to 18, wherein each of the one or more tubes is formed from a single grade steel, and this single grade steel includes 1500 grade steel. [Examples]

[0069] A rocker panel according to any of Examples 5 to 18, wherein each of the one or more tubes is formed from a steel of multiple grades. [Examples]

[0070] A rocker panel according to Example 21, wherein at least one of the multiple grades of steel includes two-phase 780 grade steel or 1500 grade steel. [Examples]

[0071] A rocker panel according to any of Examples 5 to 22, wherein the one or more pipes include a plurality of pipes, and each of the plurality of pipes is joined to other adjacent pipes by a joining method. [Examples]

[0072] A rocker panel according to Example 23, wherein the joining method includes welding. [Examples]

[0073] A rocker panel according to Example 24, wherein the welding includes laser welding. [Examples]

[0074] A rocker panel according to Example 25, wherein the joining method includes mechanical fastening. [Examples]

[0075] A rocker panel as described in Example 23, wherein the joining method includes chemical fastening. [Examples]

[0076] A rocker panel according to Example 23, wherein the joining method includes a combination of selected joining methods, the combination of joining methods including one or more of welding, mechanical fastening, and chemical fastening. [Examples]

[0077] A rocker panel used in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, the reinforcing structure comprising a plurality of individual steel pipes arranged in a predetermined arrangement between the inner plate and the outer plate, the predetermined arrangement comprising a reinforcing structure extending longitudinally between the outer plate and the inner plate, A rocker panel having the following features. [Examples]

[0078] A rocker panel according to Example 29, wherein the plurality of individual tubes include a pair of longitudinal tubes stacked on top of each other and a single transverse tube positioned adjacent to the longitudinal tubes. [Examples]

[0079] A rocker panel according to Example 29, wherein the plurality of individual tubes include a pair of lateral tubes arranged side by side and a pair of longitudinal tubes arranged adjacent to at least one of the lateral tubes of the pair. [Examples]

[0080] A rocker panel according to Example 31, wherein the pair of longitudinal pipes are further stacked such that one longitudinal pipe is positioned on top of the other longitudinal pipe. [Examples]

[0081] A rocker panel according to Example 29, wherein the plurality of individual tubes include four longitudinally oriented tubes arranged in a 4x4 grid. [Examples]

[0082] A rocker panel according to Example 33, wherein the 4x4 grid of the four longitudinal pipes includes one row of longitudinal pipes that has a longer longitudinal dimension than the other rows of longitudinal pipes. [Examples]

[0083] A rocker panel according to Example 29, wherein the plurality of individual tubes include a plurality of square tubes and a single rectangular tube arranged adjacent to the plurality of square tubes. [Examples]

[0084] A rocker panel according to Example 35, wherein the plurality of square tubes include four square tubes, and these four square tubes are arranged in a 4x4 grid. [Examples]

[0085] A rocker panel according to Example 36, wherein the longitudinal dimension of the single rectangular tube is approximately equal to the dimension of one row of the four square tubes in the 4x4 grid. [Examples]

[0086] A rocker panel according to Example 29, wherein the plurality of individual tubes include a trapezoidal tube positioned between two rectangular or square tubes. [Examples]

[0087] A rocker panel according to Example 29, wherein the plurality of individual tubes include a pair of square tubes, a trapezoidal tube, and a rectangular tube, the trapezoidal tube being positioned between the pair of square tubes and the rectangular tube. [Examples]

[0088] A rocker panel according to Example 39, wherein the trapezoidal tube defines a first dimension and a second dimension, the first dimension being greater than the second dimension, the pair of square tubes are adjacent to the surface of the trapezoidal tube defining the first dimension, and the rectangular tubes are adjacent to the surface of the trapezoidal tube defining the second dimension. [Examples]

[0089] A rocker panel according to Example 29, wherein the plurality of individual tubes include an outer tube and an inner tube, and the inner tube is located inside at least a portion of the outer tube. [Examples]

[0090] A rocker panel according to Example 41, wherein the inner tube is completely surrounded by the outer tube. [Examples]

[0091] A rocker panel according to Example 41 or 42, wherein the reinforcing structure further includes at least one web, the at least one web extending from the inner tube to the outer tube to form a single, integrated structure. [Examples]

[0092] A rocker panel according to any one of Examples 41 to 43, wherein the outer tube defines a bow tie-shaped cross-section, and the inner tube defines a rectangular cross-section.

Claims

1. A rocker panel used in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, the reinforcing structure including one or more individual steel pipes extending longitudinally between the outer plate and the inner plate, A rocker panel having the following features.

2. A rocker panel according to claim 1, wherein the reinforcing structure includes three tubes arranged along an axis extending from the outer plate to the inner plate.

3. A rocker panel according to claim 2, wherein the pipes are arranged in a single row.

4. A rocker panel according to claim 1, wherein the reinforcing structure includes five pipes, and one or more of the pipes are arranged to extend continuously from the outer plate to the inner plate.

5. A rocker panel according to claim 4, wherein four of the five pipes are arranged in a 4x4 grid pattern, and one of the five pipes is arranged adjacent to the 4x4 grid pattern.

6. A rocker panel according to claim 4 or 5, wherein the pipes are arranged symmetrically along a common axis extending from the outer plate to the inner plate.

7. A rocker panel according to claim 6, wherein the common axis is oriented perpendicular to a portion of the outer plate and a portion of the inner plate.

8. A rocker panel according to claim 1, wherein the reinforcing structure includes two tubes, the two tubes being arranged to extend continuously from the outer plate to the inner plate.

9. A rocker panel according to claim 8, wherein the two tubes form a row extending from the outer plate to the inner plate.

10. A rocker panel according to claim 1, wherein the reinforcing structure includes a single tube extending from the surface of the outer plate to the surface of the inner plate.

11. A rocker panel according to any one of claims 1 to 10, wherein each of the one or more pipes defines a square cross-section.

12. A rocker panel according to any one of claims 1 to 10, wherein each of the one or more pipes defines a circular cross-section.

13. A rocker panel according to any one of claims 1 to 12, wherein each of the one or more pipes has a defined wall thickness, and this wall thickness is 1 to 2 mm.

14. A rocker panel according to claim 13, wherein the wall thickness is 1.2 mm or 1.8 mm.

15. A rocker panel according to any one of claims 1 to 14, wherein each of the one or more tubes is made of a single-grade steel, and this single-grade steel includes two-phase 780 grade steel.

16. A rocker panel according to any one of claims 1 to 14, wherein each of the one or more tubes is formed from a single grade steel, and this single grade steel includes 1500 grade steel.

17. A rocker panel according to any one of claims 1 to 14, wherein each of the one or more tubes is formed from a steel of multiple grades.

18. A rocker panel according to claim 17, wherein at least one of the multiple grades of steel includes two-phase 780 grade steel or 1500 grade steel.

19. A rocker panel according to any one of claims 1 to 18, wherein the one or more pipes include a plurality of pipes, and each of the plurality of pipes is joined to other adjacent pipes by a joining method.

20. A rocker panel according to claim 19, wherein the joining method includes welding.

21. A rocker panel according to claim 20, wherein the welding includes laser welding.

22. A rocker panel according to claim 21, wherein the joining method includes mechanical fastening.

23. A rocker panel according to claim 19, wherein the joining method includes chemical fastening.

24. A rocker panel according to claim 19, wherein the joining method includes a combination of selected joining methods, the combination of joining methods including one or more of welding, mechanical fastening, and chemical fastening.

25. A rocker panel used in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, the reinforcing structure comprising a plurality of individual steel pipes arranged in a predetermined arrangement between the inner plate and the outer plate, the predetermined arrangement comprising a reinforcing structure extending longitudinally between the outer plate and the inner plate, A rocker panel having the following features.

26. A rocker panel according to claim 25, wherein the plurality of individual pipes include a pair of longitudinal pipes stacked on top of each other and a single transverse pipe positioned adjacent to the longitudinal pipe.

27. A rocker panel according to claim 25, wherein the plurality of individual pipes include a pair of lateral pipes arranged side by side and a pair of longitudinal pipes arranged adjacent to at least one of the lateral pipes of the pair.

28. A rocker panel according to claim 27, wherein the pair of longitudinal pipes are further stacked such that one longitudinal pipe is positioned on top of the other longitudinal pipe.

29. A rocker panel according to claim 25, wherein the plurality of individual tubes include four longitudinally oriented tubes arranged in a 4x4 grid.

30. A rocker panel according to claim 29, wherein the 4x4 grid of the four longitudinal pipes includes one row of longitudinal pipes that has a longer longitudinal dimension than the other rows of longitudinal pipes.

31. A rocker panel according to claim 25, wherein the plurality of individual tubes include a plurality of square tubes and a single rectangular tube arranged adjacent to the plurality of square tubes.

32. A rocker panel according to claim 31, wherein the plurality of square tubes include four square tubes, and these four square tubes are arranged in a 4x4 grid.

33. A rocker panel according to claim 32, wherein the longitudinal dimension of the single rectangular tube is approximately equal to the dimension of one row of the four square tubes in the 4x4 grid.

34. A rocker panel according to claim 25, wherein the plurality of individual tubes include a trapezoidal tube positioned between two rectangular or square tubes.

35. A rocker panel according to claim 25, wherein the plurality of individual tubes include a pair of square tubes, a trapezoidal tube, and a rectangular tube, the trapezoidal tube being positioned between the pair of square tubes and the rectangular tube.

36. A rocker panel according to claim 35, wherein the trapezoidal tube defines a first dimension and a second dimension, the first dimension being greater than the second dimension, the pair of square tubes are adjacent to the surface of the trapezoidal tube defining the first dimension, and the rectangular tubes are adjacent to the surface of the trapezoidal tube defining the second dimension.

37. A rocker panel according to claim 25, wherein the plurality of individual tubes include an outer tube and an inner tube, and the inner tube is located inside at least a portion of the outer tube.

38. A rocker panel according to claim 37, wherein the inner tube is completely surrounded by the outer tube.

39. A rocker panel according to claim 37 or 38, wherein the reinforcing structure further includes at least one web, the at least one web extending from the inner tube to the outer tube to form a single, integrated structure.

40. A rocker panel according to any one of claims 37 to 39, wherein the outer tube defines a bow tie-shaped cross-section, and the inner tube defines a rectangular cross-section.

41. A rocker panel for use in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, This reinforcing structure includes one or more individual steel pipes positioned between the outer plate and the inner plate, defining an asymmetrical configuration from one side to the other of the rocker panel, wherein the asymmetrical configuration has square or rectangular pipe sections on their opposing sides, and tapered pipe sections are positioned between the square or rectangular pipe sections. A rocker panel having

42. A rocker panel according to claim 41, wherein the asymmetric configuration is configured to provide one of the outer plate or the inner plate with more structural material than the other of the inner plate or the outer plate.

43. A rocker panel according to claim 41, wherein the reinforcing structure includes a single tube extending from the surface of the outer plate to the surface of the inner plate.

44. A rocker panel according to claim 41, wherein the one or more individual steel pipes include a pair of square pipes, a trapezoidal pipe, and a rectangular pipe, and the trapezoidal pipe is positioned between the pair of square pipes and the rectangular pipe.

45. A rocker panel according to claim 44, wherein the pair of square tubes define one of the square tube or the rectangular tube portion, the trapezoidal tube defines the tapered tube portion, and the rectangular tube defines the other of the square tube or the rectangular tube portion.

46. A rocker panel according to claim 44, wherein the trapezoidal tube defines a first dimension and a second dimension, the first dimension being larger than the second dimension, the pair of square tubes are adjacent to the surface of the trapezoidal tube defining the first dimension, and the rectangular tubes are adjacent to the surface of the trapezoidal tube defining the second dimension.

47. A rocker panel according to claim 41, wherein the tapered tube portion defines a first dimension and a second dimension, the first dimension being greater than the second dimension, one square or rectangular tube portion is adjacent to a portion of the tapered tube portion defining the first dimension, and another square or rectangular tube portion is adjacent to a portion of the tapered tube portion defining the second dimension.

48. A rocker panel according to claim 41, wherein the reinforcing structure is defined by a plurality of individual steel pipes, and each of the plurality of individual steel pipes is aligned along a common axis extending perpendicular to the inner plate and the outer plate.

49. A rocker panel according to claim 41, wherein the tapered pipe portion is defined by a single trapezoidal pipe.

50. A rocker panel used in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, This reinforcing structure includes one or more individual steel pipes positioned between the outer plate and the inner plate, The aforementioned one or more individual steel pipes define an asymmetrical configuration in which more structural material is placed on one side of a rocker panel that defines a relatively high height and a relatively low height. The one or more individual steel pipes have a reinforcing structure that tapers from the relatively high height to the relatively low height, A rocker panel having the following features.

51. A rocker panel according to claim 50, wherein the one or more individual steel pipes include a trapezoidal pipe, and the trapezoidal pipe defines the taper from the relatively high height to the relatively low height.

52. A rocker panel according to claim 50, wherein the one or more individual steel pipes include a pair of square pipes, a trapezoidal pipe, and a rectangular pipe, the trapezoidal pipe being positioned between the pair of square pipes and the rectangular pipe, and the trapezoidal pipe defining the taper from the relatively high height to the relatively low height.

53. A rocker panel used in a vehicle, (a) Outer plate and (b) Inner plate and (c) A reinforcing structure disposed between the inner plate and the outer plate, the reinforcing structure including one or more individual steel pipes disposed between the outer plate and the inner plate, The one or more individual steel pipes define a first rectangular pipe section, a second rectangular pipe section, and a tapered pipe section, and the tapered pipe section is provided with a reinforcing structure positioned between the first rectangular pipe section and the second rectangular pipe section. A rocker panel having the following features.

54. A rocker panel according to claim 53, wherein the one or more individual steel pipes include a pair of square pipes, a trapezoidal pipe, and a rectangular pipe, and the trapezoidal pipe is positioned between the pair of square pipes and the rectangular pipe.

55. A rocker panel according to claim 54, wherein the pair of square tubes define the first rectangular tube section, the trapezoidal tube defines the tapered tube section, and the rectangular tube defines the second rectangular tube section.

56. A rocker panel according to claim 54, wherein the trapezoidal tube defines a first dimension and a second dimension, the first dimension being greater than the second dimension, the pair of square tubes are adjacent to the surface of the trapezoidal tube defining the first dimension, and the rectangular tubes are adjacent to the surface of the trapezoidal tube defining the second dimension.

57. A rocker panel according to claim 53, wherein the tapered tube portion defines a first dimension and a second dimension, the first dimension being larger than the second dimension, the first rectangular tube portion being adjacent to a part of the tapered tube portion defining the first dimension, and the second rectangular tube portion being adjacent to a part of the tapered tube portion defining the second dimension.

58. A rocker panel according to claim 53, wherein the reinforcing structure is defined by a plurality of individual steel pipes, and each of the plurality of individual steel pipes is aligned along a common axis extending perpendicular to the inner plate and the outer plate.

59. A rocker panel according to claim 53, wherein the tapered pipe portion is defined by a single trapezoidal pipe.

60. A rocker panel according to claim 53, wherein the one or more individual steel pipes are arranged to define an asymmetrical configuration from one side to the other side of the rocker panel.

Images