Beam assembly with multiple hollow structures

Abstract

A beam assembly includes a first beam having a first tubular portion and a first protruding portion extending from the first tubular portion. The beam assembly also includes a second beam having a second tubular portion and a second protruding portion extending from the second tubular portion. The elongated interior of the first tubular portion defines a first hollow area, and the elongated interior of the second tubular portion defines a second hollow area. The first beam is attached to the second beam, wherein the first protruding portion is attached to the second tubular portion and the second protruding portion is attached to the first tubular portion to define a third hollow area between the first protruding portion and the second protruding portion.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 62 / 979,457, filed on February 21, 2020, the disclosure of which is considered a part of this application and is incorporated by reference in its entirety into this application. Technical Field

[0003] The present invention relates generally to a beam assembly and more particularly to a tubular beam having at least one hollow interior, such as for use as a vehicle bumper reinforcement, a structural frame member, a battery tray member, or the like. Background Art

[0004] Vehicle beams used for reinforcement and structural support are typically designed for specific vehicle applications and mounting locations on the vehicle. The cross-sectional shape of beams used as vehicle structural components is typically designed to have a geometry that corresponds to the packaging space, bending strength, and impact energy management characteristics required for the application and location in the vehicle structure. In addition, roll-formed beams designed for specific components require a set of customized roll tools, so that changes to the cross-sectional shape or design of the roll-formed beams typically require expensive investments in additional customized roll tools. Summary of the invention

[0005] The present invention provides a beam assembly that combines multiple elongated beams into a single elongated beam assembly. The beam assembly may include multiple beam segments cut from a single elongated beam and attached together in parallel alignment relative to each other to provide a more stable elongated beam structure having a desired cross-sectional shape, such as a cross-sectional shape having multiple hollow areas and / or multiple shear walls. Therefore, at least some of the beam segments attached together to form the beam assembly may each have the same cross-sectional shape. This allows the desired cross-sectional features of the beam assembly to be achieved with fewer tools that would otherwise be necessary to form a single beam having similar cross-sectional features to the beam assembly.

[0006] According to one aspect of the present invention, a beam assembly includes a first beam having a first tubular portion and a first protruding portion, the first protruding portion extending from a first seam along the first tubular portion. The beam assembly also includes a second beam having a second tubular portion and a second protruding portion, the second protruding portion extending from a second seam along the second tubular portion. The elongated interior of the first tubular portion defines a first hollow area, and the elongated interior of the second tubular portion defines a second hollow area. The first beam is attached to the second beam, wherein the first protruding portion is attached to the second tubular portion and the second protruding portion is attached to the first tubular portion to define a third hollow area between the first protruding portion and the second protruding portion.

[0007] In some embodiments, the first beam and the second beam each have the same cross-sectional shape, such as a P-shaped cross-section extending continuously along the length of the respective beams. In addition, in some examples, the first beam is vertically disposed above the second beam, and the lower wall of the first beam and the upper wall of the second beam can be substantially flat and parallel to define an internal shear wall of the beam assembly.

[0008] In further embodiments, the beams may each be roll-formed from a metal sheet made of high strength steel, ultra high strength steel or other metals such as aluminum. The first beam and the second beam may be attached together by welding, such as continuous welding along the length of the first beam and the second beam.

[0009] In other aspects, the beam assembly can include a third beam having a third tubular portion and a third protruding portion, the third protruding portion extending from the third seam along the third tubular portion. The third beam can have the same cross-sectional shape as the first beam and the second beam. In some examples, the third beam can be attached to the second beam, wherein the third protruding portion is disposed perpendicular to the first protruding portion and the second protruding portion to form a floor support for a vehicle battery tray.

[0010] Alternatively, the beam assembly can be installed as a frame component of the vehicle, such as a rocker beam, a rocker insert, a floor cross member, a roof cross member, a pillar structure, or other vehicle structural component. In some embodiments, the beam assembly can be used as a bumper reinforcement beam, a door beam, or as part of another impact energy management structure. In addition, in some examples, the beam assembly can be used as a battery tray component, such as a tray frame wall or cross member.

[0011] According to another aspect of the present invention, a beam assembly includes a first beam having a first tubular portion and a first protruding portion extending along the first tubular portion. The beam assembly also includes a second beam having a second tubular portion and a second protruding portion extending along the second tubular portion. The first beam and the second beam are formed of a metal sheet so that the first tubular portion and the second tubular portion each have a seam set along their length, which is defined by an edge section of the metal sheet attached along a central section of the metal sheet. The first protruding portion and the second protruding portion protrude integrally from the central section of the metal sheet at the seam. The first beam is attached to the second beam, wherein the first protruding portion is attached to the second tubular portion and the second protruding portion is attached to the first tubular portion to define a hollow area between the first protruding portion and the second protruding portion.

[0012] These and other objects, advantages, purposes and features of the present invention will become apparent from a reading of the following description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a top perspective view of a vehicle schematically illustrating various examples of beam assemblies;

[0014] Figure 2 yes Figure 1 a side view of a vehicle shown in , schematically illustrating other examples of beam assemblies;

[0015] Figure 3 is a top perspective view of an exemplary beam assembly;

[0016] Figure 3A yes Figure 3 A cross-sectional perspective view of the beam assembly shown in FIG. 1 taken along line AA;

[0017] Figure 4 yes Figure 3 an end view of the beam assembly shown in;

[0018] Figure 5-10 are end views of other examples of beam assemblies;

[0019] Fig.11 is a side view of a vehicle schematically illustrating additional examples of beam assemblies of a battery tray structure; and

[0020] Fig.12 yes Fig.11 A cross-sectional view of a side wall portion of a battery tray structure shown in FIG. DETAILED DESCRIPTION

[0021] Referring now to the drawings and the embodiments shown therein, there is provided a beam assembly that can be used in various beam applications, such as components or structures for motor vehicles, including electric vehicles (EVs) and internal combustion engine (ICE) vehicles, e.g. Figure 1 and Figure 2 The vehicle 100 shown in FIG. Figure 3-Figure 12 As shown, the beam assembly combines multiple slender beams into a single slender beam assembly. Figure 3-Figure 4 As shown, the beam assembly 10 includes a first beam 12, the first beam 12 having a tubular portion 14 and a protruding portion 18, the tubular portion 14 having an elongated hollow interior 16, and the protruding portion 18 protruding outwardly from a seam extending along the tubular portion 14. The beam assembly 10 also includes a second beam 22, the second beam 22 also having a tubular portion 24 and a protruding portion 28, the tubular portion 24 having an elongated hollow interior 26, and the protruding portion 28 protruding outwardly from a seam extending along the tubular portion 24. Therefore, the first beam 12 and the second beam 22 can each have the same cross-sectional shape, such as a P-shaped cross-section. In the case of having substantially the same cross-sectional shape, before assembly, the first beam 12 and the second beam 22 can be cut from a single elongated beam (e.g., a continuous roll-formed beam). The first beam 12 and the second beam 22 are attached together in a parallel alignment and side by side manner to form a desired cross-sectional shape of the entire beam assembly 10 in combination.

[0022] To form the beam assembly 10, the first beam 12 and the second beam 22 may be arranged in a reversed mirror image relationship in a longitudinal plane extending axially between the tubular portions 14, 24 of the first beam 12 and the second beam 22. In other words, when the first beam 12 and the second beam 22 are initially in the same orientation, one of the beams is axially rotated about 180 degrees along its longitudinal axis relative to the other beam before the beams 12 and 22 are attached together. Figure 3-Figure 4 As shown, the first beam 12 is attached to the second beam 22, wherein the protruding portion 18 of the first beam 12 is attached to the tubular portion 24 of the second beam 22 and the protruding portion 28 of the second beam 22 is attached to the tubular portion 14 of the first beam 12 to define at least two separate attachment points 30 or seams disposed longitudinally between the beams 12, 22 along the length of the beam assembly 10. The attachment points 30 may be formed by welding, such as by continuous welds or intermittent spot welds, or may be formed by other types of attachment means, such as adhesives or fasteners, etc.

[0023] like Figure 3-Figure 4 As shown, opposing walls 34 facing each other in the tubular portions 14, 24 of the first beam 12 and the second beam 22 can be spaced apart from each other to define an elongated hollow region 32 between the beams 12, 22. The hollow region 32 is also defined between the protruding portions 18, 28 of the beams 12, 22. Because this spacing provides a defined central hollow region 32 of the beam assembly 10, the opposing walls 34 of the tubular portions 14, 24 can be used to strengthen the entire interior region of the beam assembly 10, such as by serving as an interior shear wall of the beam assembly 10. In addition, the opposing walls 34 of the beam assembly 10 divide the interior region to provide a multi-hollow shape defined by the hollow interiors 16, 26 of the tubular portions 14, 24 of the respective beams 12, 22 and the central or third hollow region 32 disposed between the tubular portions 14, 24. It is contemplated that other examples of beam assemblies may have various alternative cross-sectional shapes and configurations, such as having additional or alternative beams, attachment points, or hollow regions to provide a desired cross-sectional shape for the beam assembly.

[0024] Likewise, for example Figure 3-Figure 4 As shown, the peripheral cross-sectional shape of the beam assembly 10 may have a rectangular shape. In addition, the tubular portions 14, 24 may each have a generally rectangular cross-sectional shape defined by four orthogonally arranged wall segments. For example Figure 4As shown, the beams 12, 22 can be roll-formed from sheet metal to form tubular portions 14, 24 having a first wall segment 34, a second wall segment 36, a third wall segment 38, and a fourth wall segment 40, which together form a rectangular cross-sectional shape. The tubular portions 14, 24 have three rounded corners 42, which are defined by the bending radius of the sheet metal, which can be limited by the material thickness and material ductility, for example, greater than about four times the thickness of the sheet metal. The beams can each be roll-formed from sheet metal made of high-strength steel, ultra-high-strength steel, or other metals such as aluminum.

[0025] like Figure 4 As shown, the remaining square corners 44 of the tubular portions 14, 24 are formed by attaching the edge 46 of the first wall segment 34 to the metal sheet at an intermediate position between the fourth wall segment 40 and the protruding portions 18, 28. The seam formed at the edge 46 of the metal sheet can be attached by welding the edge 46 to the metal sheet, such as by forming a fillet weld, etc. Such welding can be accomplished, for example, by intermittent spot welding or continuous welding along the beam. The first wall segment 34 on the metal sheet forms a seam at the attachment location and generally separates the fourth wall segment 40 from the protruding portions 18, 28. As shown in FIG. Figure 4 As shown, the projections 18, 28 extend from the tubular portions 14, 24 in planar alignment with the respective fourth wall segments 40. When the two separate beams 12, 22 are attached together, the third hollow area 32 formed between the beams is surrounded by the projections 18, 28 and the fourth wall segments 40 of the tubular portions 14, 24.

[0026] Further references Figure 3-Figure 4 , the tubular portions 14, 24 may each include a recessed area 48 to accommodate the edge of the other beam projection 18, 28. Figure 4 As shown, the recessed area 48 is provided at the second wall section 36 and has a depth that projects inwardly into the respective hollow interior area 16 , 26 by a distance that is substantially equal to the thickness of the joining edges of the protruding portions 18 , 28 . Figure 4 The approximate depth of each recessed area 48 shown is measured between the flat outer surface of the second wall segment 36 and the flat outer surface at the recessed area 48, which is generally equal to the thickness of the metal sheet of another beam. The recessed area 48 generally aligns the flat outer surface of the second wall segment 36 with the outer surface of the attached projections 18, 28, which may also be aligned with the outer surface of the fourth wall segment 40 from which the respective projections 18, 28 extend. The aligned projections 18, 28, the second wall segment 36, and the fourth wall segment 40 together form parallel and opposing outer walls of the entire beam assembly 10.

[0027] Reference Figure 5-10, showing the beam assembly 110 ( Figure 5 )、210( Figure 6 )、310( Figure 7 )、410( Figure 8 )、510( Fig. 9 )、610( Fig.10 ) to show other examples that are different from Figure 3-Figure 4 Alternative cross-sectional shapes to those shown. For example, Figure 5 In the orientation shown, the beam assembly 110 has a Figure 4 The beam assembly 10 is shown with a reduced horizontal width. The reduced width of the beam assembly 110 is provided by the tubular portion 114, 124 of each beam 112, 122 having a reduced width, and more specifically, the first wall section 134 and the third wall section 138 having a shorter length. Figure 5 The beam assembly 110 shown may be composed of Figure 4 The beam assembly 10 shown has the second wall segment 136 and the fourth wall segment 140 of substantially the same length, the same length of the projections 118, 128, and the same number of curved portions. Figure 5 The radius of curvature at the mid-corner curved portion 142 is greater than Figure 4 The radius of curvature at the mid-corner curved portion 42 is used to form Figure 5 The total width of the metal sheet of each beam 112, 122 of the center beam assembly 110 is less than the width of the metal sheet used to form the center beam assembly 110. Figure 4 The width of the metal plate of the center beam 12 , 22 .

[0028] In addition, if Figure 6 As shown in the direction of Figure 4 The beam assembly 10 shown in FIG. 1 has the same rectangular outer cross-sectional shape, but with closer inner shear walls. The closer shear walls are provided by the tubular portions 214, 224 of each beam 212, 222 having increased heights, and more specifically, the second wall segment 236 and the fourth wall segment 240 having longer lengths. In order to maintain Figure 4 and Figure 6 The center beam assemblies 10 and 210 have the same overall height. Figure 6 The shortened length of the protruding portions 218, 228 of the center beam assembly 210 is equal to the increased height of the tubular portion as a whole. Figure 6 The dimensional changes shown can be formed with the same metal sheet, bending structure and rolling tool, but changing the position of the rolling tool on the roll forming line. Therefore, the beam assembly in different examples can include various dimensional changes.

[0029] The beam assembly may also include one or more channel ribs to strengthen a portion of the beam assembly. Figure 7As shown, the protruding portions 318, 328 of the beam assembly 310 each include a groove rib 320 located at a central section thereof and extending along the length of the corresponding beam 312, 322. By arranging the groove rib 320 on the protruding portions 318, 328, the groove rib 320 is disposed at a central vertical position of the beam assembly 310 and protrudes inwardly on opposite sides of the center or third hollow area 332. Figure 7 The beam assembly 310 shown in FIG. 1 is otherwise similar to Figure 4 The beam assembly 10 shown in FIG. 1 may be such that the variation in the groove ribs may be achieved by increasing the width of the metal sheet and adding a rolling tool that forms the groove ribs 320 in the protruding portion. In further examples, it is contemplated that additional groove ribs may be provided at other portions of the beam assembly, such as at various wall sections of the tubular portion.

[0030] like Figure 8 As further shown in FIG. 1 , the beam assembly 410 has Figure 4 The beam assembly 10 shown in FIG. 1 has the same overall cross-sectional shape except for the manner in which the edge portion 446 of the first wall segment 434 is attached to the metal plate. Figure 8 As shown, the seam formed at the edge portion 446 of the metal sheet may include a corner bend 442 so that the flat side surface of the metal sheet at the edge portion 446 is attached to the flat side surface of the metal sheet between the fourth wall segment 440 and the protruding portions 418, 420. This flat surface attachment can be provided by welding, such as by intermittent spot welding or continuous welding along the beam. For example, a laser weld can be formed by orienting a laser head generally perpendicular to the outer surface of the metal sheet so that the laser weld can be formed vertically through the overlapping portion of the metal sheet and the edge portion 446. As shown in FIG. Figure 8 As shown, the edge portion 446 is bent to extend into the hollow interior region 416, 426 of the corresponding beam 412, 422. Figure 8 As shown, the projections 418 , 428 extend from the tubular portions 414 , 424 in planar alignment with the edge portion 446 and the respective fourth wall segment 440 .

[0031] Similarly, if Fig.10 As shown, the beam assembly 610 has Figure 8 The beam assembly 410 shown in FIG. 4 has the same overall cross-sectional shape and edge portion attachment method, except for the attachment method of the protruding portions 618, 628 to the other corresponding beam tubular portions 614, 624. Fig.10As shown, the edges of the protrusions 618, 628 may also include corner bends 642 so that the flat side surfaces of the metal sheet at the protrusions 618, 628 are attached to the flat side surfaces of the first wall segment 634. This flat surface attachment may be provided by welding, such as by intermittent spot welding or continuous welding along the beam. For example, a laser weld may be formed along the seam by orienting the laser head generally perpendicular to the outer surfaces of the second wall segment 636 and the protrusions 618, 628. In addition, as shown in FIG. Fig.10 As shown, the edges of the protruding portions 618, 628 are bent to extend to the central interior region 632. This allows the recessed region to be omitted from the second wall section.

[0032] In addition, if Fig. 9 As shown, the protruding portions 518, 528 are attached to the tubular portions 514, 524 and extend beyond the tubular portions to provide flanges 550, 552 for attachment to adjacent vehicle components. For example, the flanges 550, 552 can be used to attach the beam assembly 510 between the inner and outer sills, or can be used to replace either or both sill components. In different examples, the flanges can be alternatively shaped or positioned to provide a flange design that accommodates a corresponding vehicle design. Fig. 9 As shown, the protruding portions 518, 528 are disposed above another second wall segment 536, and each protruding portion has a curved portion corresponding to the corner curved portion 542 between the second wall segment 536 and the third wall segment 538, so that the protruding portions 518, 528 extend along and above the third wall segment 538. Fig. 9 As further shown, the projection has an outwardly directed bend that directs the flanges 550 , 552 perpendicularly outwardly from the third wall section 538 .

[0033] Reference Fig.11 and Fig.12 , the beam assembly 710 includes a third beam 752 having a tubular portion 754 having an elongated hollow interior 756 and a protruding portion 758 extending from the tubular portion 754. Fig.12 As shown, the third beam 752 has the same cross-sectional shape as the first beam 712 and the second beam 722, which is shown as a P-shaped cross-section. Therefore, the three beams 712, 722, 752 can be cut from a single elongated beam (e.g., a continuous roll-formed beam). The beams 712, 722, 752 are attached together in parallel alignment and side by side with each other to form the desired cross-sectional shape of the beam assembly 710 having four hollow interior areas.

[0034] like Fig.11 and Fig.12As further shown in FIG. 1 , the third beam 752 is attached to the second beam 722, wherein the protruding portion 758 of the third beam 752 is arranged perpendicular to the other protruding portions 718, 728 and is attached to the bottom wall section 738 of the bottom tubular portion. The first wall section 734 of the tubular portion 754 of the third beam 752 is also attached to the second wall section 736 of the bottom tubular portion. With this cross-sectional shape, Fig.12 The beam assembly 710 shown may be used as a side wall 760 of a battery tray 762, for example Fig.11 As shown. The tubular portion 754 of the third beam 752 can be arranged on the outside of the side wall 760 to assist in absorbing the energy of a side impact. In addition, the protruding portion 758 of the third beam 752 can be arranged on the inside of the side wall 760 to form a floor support for the floor 764 of the battery tray 762 and any other internal components of the battery tray 762.

[0035] For various vehicle applications, the beam assembly can be used as, for example, a vehicle bumper reinforcement, a structural frame component, a battery tray component. Figure 1 and Figure 2 As shown, these applications include, for example, roof bows 102, window eyebrows 103, pillars 104, door sills 105, floor cross members 106, bumper beams 107, door beams 108, frame rail ends 109, etc. Figure 1 and Figure 2 As shown, the beam assembly can be designed to withstand various impact forces, such as for vehicle bumper reinforcement beam 107 and door beam 108. Figure 1 and Figure 2 The exemplary vehicle 100 shown in FIG. 1 further provides that the vehicle 100 has a body structure or frame 101 having a plurality of structural beam members, one or all of which may be configured as beam assemblies as described herein. For example, the beam assemblies may be designed to support and sustain different load conditions, such as for supporting horizontal spans (such as roof bows 102 and rocker beams 105 or inserts thereof), or for supporting axial loads (such as vehicle frame pillars 104). In addition, as Fig.11 In the vehicle 700 shown in FIG. 7 , the beam assembly may be used as a structural component of the battery tray 762 , such as an outer edge side wall 760 or a cross member spanning between opposing side walls of the battery tray.

[0036] The cross-sectional shape of the beam assembly may include various shapes and thicknesses for the desired application of the beam assembly, such as an open profile or a closed profile, which may include a multi-tube profile having two or more hollow interior regions extending longitudinally within the pultruded profile.

[0037] For the purposes of the present invention, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and their derivatives shall be used in the same manner as in the present invention. Figure 1oriented therein. However, it should be understood that the device may assume various alternative orientations unless otherwise expressly provided to the contrary. It should also be understood that the specific devices and processes shown in the drawings and described in this specification are merely exemplary embodiments or implementations. Accordingly, the terms used are intended to be descriptive rather than restrictive. Therefore, specific dimensions and other physical characteristics associated with the embodiments or implementations disclosed herein should not be considered restrictive unless otherwise expressly provided in the claims. Various modifications and variations of the embodiments and implementations are possible in light of the above teachings.

Claims

1. A beam assembly comprising: a first beam having a first tubular portion and a first protruding portion extending along the first tubular portion, wherein the first tubular portion surrounds a first hollow region; a second beam having a second tubular portion and a second protruding portion extending along the second tubular portion, wherein the second tubular portion surrounds a second hollow region; wherein the first beam is attached to the second beam, wherein the first protruding portion is attached to the second tubular portion and the second protruding portion is attached to the first tubular portion to define a third hollow region between the first protruding portion and the second protruding portion; and A third beam having a third tubular portion and a third protruding portion extending along the third tubular portion, wherein the first beam, the second beam, and the third beam each include a same cross-sectional shape, wherein the third beam is attached to the second beam via the third protruding portion, and wherein the third protruding portion is perpendicular to the first protruding portion and the second protruding portion.

2. The beam assembly according to claim 1, wherein: The first beam and the second beam each include the same cross-sectional shape.

3. The beam assembly according to claim 2, wherein: The same cross-sectional shape is a P-shape.

4. The beam assembly according to claim 3, wherein: The same cross-sectional shape extends continuously along a length of each of the first beam and the second beam.

5. The beam assembly according to claim 4, wherein: The first beam and the second beam are attached together by welding.

6. A beam assembly according to any one of the preceding claims, wherein: The first tubular portion includes a rectangular cross-sectional shape defined by four wall segments, and wherein the first protruding portion extends from the first tubular portion, the first tubular portion being aligned with a plane of the four wall segments.

7. The beam assembly of claim 6, wherein: The third hollow area is surrounded by the first and second protruding portions and parallel wall sections of the first and second tubular portions.

8. The beam assembly of claim 1, wherein: The first and second projecting portions each include a channel rib extending along a length of the respective first and second beams, and wherein the channel ribs are disposed on opposite sides of the third hollow region.

9. The beam assembly of claim 1, wherein: The wall of the first tubular portion includes a flat portion and a recessed portion, the recessed portion being configured to engage the second protruding portion, and wherein the flat portion of the wall of the first tubular portion is disposed in alignment with the second protruding portion and together forms an outer wall of the beam assembly.

10. The beam assembly of claim 1, wherein: The first and second projecting portions extend outwardly from attachments to the respective first or second tubular portions to define flanges, and wherein the beam assembly comprises at least one component of a rocker section.

11. A beam assembly comprising: a first beam having a first tubular portion and a first protruding portion extending along the first tubular portion; a second beam having a second tubular portion and a second protruding portion extending along the second tubular portion; wherein the first beam and the second beam are formed of sheet metal, the first tubular portion and the second tubular portion each have a seam along a length thereof, the seam being defined by edge sections of the sheet metal attached along a central section of the sheet metal, and the first protruding portion and the second protruding portion integrally protrude from the central section of the sheet metal at the seam; wherein the first beam is attached to the second beam, wherein the first protruding portion is attached to the second tubular portion and the second protruding portion is attached to the first tubular portion to define a hollow region between the first protruding portion and the second protruding portion; and A third beam has a third tubular portion and a third protruding portion extending along the third tubular portion, wherein the third beam is attached to the second beam through the third protruding portion, and wherein the third protruding portion is attached to the first tubular portion or the second tubular portion.

12. The beam assembly of claim 11, wherein: A cross-sectional shape of the first beam taken transversely to the length is the same as a cross-sectional shape of the second beam taken transversely to the length.

13. The beam assembly of claim 12, wherein: The cross-sectional shapes of the first beam and the second beam are P-shaped.

14. The beam assembly of claim 11, wherein: The first beam and the second beam are attached together by welding.

15. The beam assembly of claim 11, wherein: The first tubular portion includes a rectangular cross-sectional shape defined by four wall segments, and wherein the first protruding portion extends from the first tubular portion, the first tubular portion being aligned with a plane of the four wall segments.

16. The beam assembly of claim 11, wherein: The first beam and the second beam each include a channel rib disposed along the length thereof.

17. The beam assembly of claim 11, wherein: The first and second protruding portions extend outwardly from attachments to the respective first or second tubular portions to define flanges.

18. The beam assembly of claim 11, wherein: A wall section of the first tubular portion includes a recessed area that engages with the second protruding portion.

19. The beam assembly according to any one of claims 11 to 18, wherein: The beam assembly includes one of the following: a roof bow, a window eyebrow, a pillar, a door sill, a cross member, a bumper beam, a door beam, a frame longitudinal beam end, or a battery tray wall.

Images