Footrest assembly insert with opposing crush grooves

Abstract

A vehicle rocker assembly includes an outer rocker member and an inner rocker member attached lengthwise along the outer rocker member to define a hollow space along and between the inner rocker member and the outer rocker member. A tubular insert is disposed in the hollow space to extend lengthwise along the hollow space. The tubular insert has an extrusion control feature extending lengthwise along a wall of the tubular insert, such as an upper wall and a lower wall at opposite sides of an interior volume. The tubular insert is configured for a lateral impact force at the outer rocker member to cause the tubular insert to laterally deform at the extrusion control feature, thereby providing an accordion-like lateral extrusion to absorb the lateral impact force.

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. 63 / 073,120, filed September 1, 2020, the disclosure of which is considered part of this application and is hereby incorporated by reference in its entirety. TECHNICAL FIELD

[0003] The present disclosure relates to rocker and rocker panel assemblies for vehicles, such as rocker structures with reinforcement inserts. BACKGROUND

[0004] Vehicles typically have a rigid frame and body structure, often referred to as a unibody frame. The frame and body structure are designed to support the vehicle during operation and to withstand and absorb a certain level of impact forces, such as distances to prevent intrusion into the passenger compartment, trunk, engine compartment, etc. according to insurance requirements and other regulations and legal requirements. With respect to impact reinforcements and structural beams used in the body or frame, it is generally known that these beams can be reinforced with internal inserts to increase stiffness. Rocker assemblies extend longitudinally along the lower portion of a unibody frame and are known to have inserts to increase stiffness, such as to reduce side impact intrusion. SUMMARY

[0005] The present disclosure provides a rocker assembly for a vehicle frame including a hollow outer structure formed with an inner and outer rocker panel member attached. A reinforcement insert is disposed within and extends longitudinally along the interior space of the hollow outer structure. The reinforcement insert has a generally uniform cross-sectional profile along the length of the rocker assembly to provide a tubular shape with one or more closed tubular sections. The reinforcement insert can be roll formed, stamped, or extruded to have a uniform cross-sectional profile, such as a closed or other tubular cross-sectional shape. To increase impact energy absorption from a lateral impact force transmitted to the outer rocker panel member, such as a side pole impactor, the reinforcement insert is provided with one or more lateral extrusion control features. The extrusion control features help control lateral compression and deformation of the rocker assembly when subjected to an impact force, such as by causing the lateral impact force to laterally deform the tubular insert in an accordion-like lateral extrusion. The extrusion control features can be provided as extrusion grooves formed along the reinforcement insert to protrude into the interior volume of the tubular shape. The extrusion grooves can be arranged at opposite sides of the reinforcement insert, such as at the upper and lower walls of the closed tubular sections of the reinforcement insert, for a lateral impact force to laterally deform the tubular insert at the extrusion grooves and provide inward or outward folding deformation, such as accordion-like lateral extrusion.

[0006] According to one aspect of the present disclosure, a vehicle rocker assembly includes an outer rocker member and an inner rocker member attached lengthwise along the outer rocker member to define a hollow space along and between the inner rocker member and the outer rocker member. A tubular insert is disposed in the hollow space to extend lengthwise along the hollow space. The tubular insert has an upper wall and a lower wall that bound opposite sides of an interior volume of the tubular insert. The upper wall and / or the lower wall of the tubular insert has an extrusion groove extending lengthwise along the tubular insert. The extrusion groove or grooves are configured to deform laterally under a lateral impact force at the outer rocker member to provide an accordion-like lateral extrusion to at least partially absorb the lateral impact force.

[0007] Implementations of the present disclosure can include one or more of the following optional features. In some implementations, the tubular insert includes an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent to each other. The outer tubular section and the inner tubular section can share a common central wall that extends vertically between the upper wall and the lower wall of the tubular insert. In some examples, the outer tubular section has an outer wall that faces the outer rocker member and is integrally interconnected between the upper wall and the lower wall of the tubular insert.

[0008] In some implementations, the extrusion groove or grooves project into the interior volume of the tubular insert, and two or more channels can be disposed at the upper wall and the lower wall at opposite sides of the interior volume. In some examples, the extrusion grooves can be mirrored across the interior volume of the tubular insert, for example, at the outer tubular section or the inner tubular section. In other examples, the extrusion grooves are vertically staggered relative to each other. Further, the upper wall and the lower wall of the tubular insert can be disposed in planar parallel alignment with each other, or can have a tapered shape. In some examples, the extrusion grooves are vertically aligned across the interior volume of the outer tubular section, for example, perpendicularly aligned relative to the upper wall and the lower wall. The extrusion grooves of the tubular insert can be configured to deform simultaneously under a lateral impact force at the outer rocker member.

[0009] With respect to securing of the tubular insert, a bracket can be attached between the upper flanges of the outer rocker member and the inner rocker member, where the bracket is attached to the tubular insert and supports the tubular insert in the hollow space. Further, in some implementations, the tubular insert includes a flange that is attached between the upper flanges of the outer rocker member and the inner rocker member, where the flange supports the tubular insert in the hollow space. Further, the tubular insert can be secured at an inner surface of the outer rocker member or the inner rocker member, for example, by at least one of welding, fasteners, or adhesive.

[0010] In some examples, the tubular insert comprises a metal plate formed as an outer tubular segment and an inner tubular segment having a common central wall, the outer and inner tubular segments being arranged laterally adjacent to each other. Alternatively, the tubular insert may be longitudinally compressed to have an outer tubular segment and an inner tubular segment having a common wall integrally interconnected with the upper and lower walls of the tubular insert.

[0011] Details of one or more implementations of this disclosure are set forth in the accompanying drawings and the following description. Other aspects, features, and advantages will be apparent from the specification, the drawings, and the claims. Attached Figure Description

[0012] Figure 1 This is a side view of the vehicle's outline, schematically showing the location of the footrest assembly.

[0013] Figure 2 yes Figure 1 The vehicle is shown in a top-down perspective view, which shows the footrest assembly and various other structural beams.

[0014] Figure 3 This is a top view of the foot pedal assembly.

[0015] Figure 4 yes Figure 3 The side view of the foot pedal assembly shown.

[0016] Figure 4A It is along Figure 4 The cross-sectional view of the foot pedal assembly is taken from line AA.

[0017] Figure 4B It is along Figure 4 The cross-sectional view of the foot pedal assembly is taken from line BB.

[0018] Figure 5 This is a top view of another instance of the footrest assembly.

[0019] Figure 6 yes Figure 5 The side view of the foot pedal assembly shown.

[0020] Figure 6A It is along Figure 6 The cross-sectional view of the foot pedal assembly is taken from line AA.

[0021] Figure 6B It is along Figure 6 The cross-sectional view of the foot pedal assembly is taken from line BB.

[0022] Figure 7 This is a top view of another instance of the footrest assembly.

[0023] Figure 8 is Figure 7 a side plan view of the rocker assembly shown in

[0024] Figure 8A is a cross-sectional view of the rocker assembly taken along line A-A in Figure 8

[0025] The same reference numbers in the various drawings represent the same elements. DETAILED DESCRIPTION

[0026] Referring now to the drawings and the exemplary embodiments described therein, a reinforced rocker assembly 10 is provided for a vehicle body structure or frame 102 of a vehicle 100, such as a Figure 1 and 2 shown. The frame and associated rocker assemblies can have various designs and configurations, such as for different styles and types of vehicles. For example, as shown in Figure 1 The vehicle 100 can utilize a battery, such as a traction battery or battery module, to at least partially operate a propulsion system of the vehicle, for example, as shown in

[0027] The vehicle rocker assembly 10 includes a hollow outer structure 12 formed with an inner rocker member 14 and an outer rocker member 16, which can also be referred to as rocker panels or sections, for example, as shown in Figures 3-4B The inner rocker member 14 is connected longitudinally along the outer rocker member 16 to define an elongated hollow space 18 between the inner and outer rocker members 14, 16. The inner and outer rocker members 14, 16 forming the outer structure 12 surround the elongated hollow space 18 between the inner and outer rocker members 14, 16. A reinforcing insert 20 is disposed in the hollow space 18 of the outer rocker structure 12 and extends longitudinally along at least a portion or longitudinal section of the hollow space 18. The reinforcing insert 20 has a substantially uniform cross-sectional profile along its length, such as a tubular shape having one or more closed tubular cross-sections. Thus, the reinforcing insert 20 can be referred to as a tubular insert.

[0028] The reinforcing insert 20 is provided with one or more lateral crush control features to increase impact energy absorption by controlling lateral compression and deformation of the rocker assembly 10 that bears lateral impact forces, such as forces delivered by a side pole impactor, for example, as shown in Figures 3-4A ​As shown, the crush grooves 22 are arranged along opposite upper and lower sides of the reinforcement insert 20. The crush grooves 22 are arranged to allow the reinforcement insert 20 to be laterally crushed like an accordion. This type of accordion-style crushing can limit breakage and material failure by controlling how the section is crushed. The controlled crushing provided by the crush grooves 22 also increases the material stack in later events, resulting in overall more energy absorption.

[0029] It is contemplated that the reinforcement inserts of the disclosed rocker assemblies can be incorporated in other types of structural beams, such as in the frames and structures of automobiles and other vehicles. Further, the reinforcement inserts can be used in other structural frame components and impact energy management beams that are configured to withstand impact loads at various sections of the beam and absorb such impact loads in a desired manner. For example, as Figure 2 As shown, the frame 102 of the vehicle 100 has a plurality of structural beams, one or all of which can be provided with internal reinforcement as described herein.

[0030] To form the outer structure 12, the inner rocker member 14 has an upper flange 14a that is connected along an upper flange 16a of the outer rocker member 16. The inner rocker member 14 also has a lower flange 14b of the inner rocker member 14 that is connected along a lower flange 16b of the outer rocker member 16. This connection of the inner and outer rocker members 14, 16 can be a direct contact engagement, or can be indirect through an intermediary, such as a flange, plate or bracket, sandwiched between the upper and lower flanges 14a, 14b, 16a, 16b. As Figures 3-4B As shown, the upper and lower flanges 14a, 14b, 16a, 16b are disposed along upper and lower edges of the inner and outer rocker members 14, 16, respectively. The upper and lower flanges 14a, 14b, 16a, 16b are also substantially planar and oriented in a generally perpendicular configuration so as to be directly contactingly connected along a portion of the length of the rocker assembly 10 ( Figure 4A ), and also indirectly connected at discrete portions where the support brackets 62 are arranged between the flanges ( Figure 4B ). The upper and lower flanges 14a, 14b, 16a, 16b are connected together by welding, although in other examples of rocker assemblies, adhesives and / or mechanical fasteners can be used in addition to or as an alternative to welding. Figure 3 The inner and outer rocker members 14, 16 are shown as being steel, but it is contemplated that other examples can include alternative or multiple materials, such as steel, aluminum and / or composite materials.

[0031] The intermediate portions of the inner and outer rocker members 14, 16 are generally disposed between the upper and lower flanges 14a, 14b, 16a, 16b and are shaped to have a generally concave cross-sectional shape, such asFigure 4A and 4B the example C-shaped cross-sections of the inner and outer side rail members 14, 16 shown in FIGS. 1 1 and 12. The intermediate portion of the inner rocker member 14 has an upper wall segment 24, an innermost wall segment 26, and a lower wall segment 28, each of which is generally planar in shape. Similarly, the intermediate portion of the outer rocker member 16 has an upper wall segment 30, an outermost wall segment 32, and a lower wall segment 34, each of which is generally planar in shape. As shown in FIGS. 1 1 and 12, the upper wall segments 24, 30 have substantially equal lengths to the respective lower wall segments 26, 34. Also, the upper and lower wall segments 24, 26, 30, 34 are each angled with respect to the horizontal, with each pair of upper and lower wall segments similarly angled. Due to the substantially equal lengths and angles, Figure 4A and 4B the upper and lower flanges 14a, 14b, 16a, 16b shown in FIGS. 1 1 and 12 are vertically aligned with one another. In other examples, the upper and lower flanges of the outer structure can be offset from one another, as shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example. Figure 4A and 4B the upper and lower flanges 14a, 14b, 16a, 16b shown in FIGS. 1 1 and 12 are vertically aligned with one another. In other examples, the upper and lower flanges of the outer structure can be offset from one another, as shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example. Figure 8A and Figures 3-6 the upper and lower flanges 14a, 14b, 16a, 16b shown in FIGS. 1 1 and 12 are vertically aligned with one another. In other examples, the upper and lower flanges of the outer structure can be offset from one another, as shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example. Figure 7 and 8 the upper and lower flanges 14a, 14b, 16a, 16b shown in FIGS. 1 1 and 12 are vertically aligned with one another. In other examples, the upper and lower flanges of the outer structure can be offset from one another, as shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example.

[0032] the example shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example. Figures 3-4B and Figure 4A the example shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example. 4B and Figure 4A the example shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example. 4B the example shown in FIG. 13, for example. Also, the cross-sectional profile of the inner panel 14 and the outer panel 16 can be generally uniform along the length of the rocker assembly, as shown in the example shown in FIGS. 1 1 and 12, or can have some non-uniform features along the length, such as to accommodate pillar junctions, as shown in the example shown in FIG. 13, for example.As shown, the crush grooves 22 are arranged on opposite sides of the interior volume 36 for lateral impact forces to cause the reinforcement insert 20 to laterally deform inward at the crush grooves 22 to provide an accordion-style lateral crush pattern. In other examples, a single crush groove can be provided, or additional crush grooves can be utilized. The crush grooves can be arranged at the upper and lower walls of the outer tubular section, while no crush grooves are provided in the other tubular sections, or alternatively, the crush grooves can be arranged at the upper and lower walls of the inner tubular section, while no crush grooves are provided in the outer tubular section, for example Figure 8A As shown.

[0033] In some examples, the crush grooves are configured to deform simultaneously under lateral impact forces at the outer rocker panel member. For example, as shown Figure 4A and 4B As shown, the crush grooves 22 are arranged on opposite sides of the interior volume 36 for lateral impact forces to cause the reinforcement insert 20 to laterally deform inward at the crush grooves 22 to provide an accordion-style lateral crush pattern. In other examples, a single crush groove can be provided, or additional crush grooves can be utilized. The crush grooves can be arranged at the upper and lower walls of the outer tubular section, while no crush grooves are provided in the other tubular sections, or alternatively, the crush grooves can be arranged at the upper and lower walls of the inner tubular section, while no crush grooves are provided in the outer tubular section, for example

[0034] The reinforcement insert 20 has an upper wall 38 and a lower wall 40 that bound opposite sides of the interior volume 36 of the reinforcement insert 20. As shown Figure 4A and 4B As shown, the crush grooves 22 are arranged on opposite sides of the interior volume 36 for lateral impact forces to cause the reinforcement insert 20 to laterally deform inward at the crush grooves 22 to provide an accordion-style lateral crush pattern. In other examples, a single crush groove can be provided, or additional crush grooves can be utilized. The crush grooves can be arranged at the upper and lower walls of the outer tubular section, while no crush grooves are provided in the other tubular sections, or alternatively, the crush grooves can be arranged at the upper and lower walls of the inner tubular section, while no crush grooves are provided in the outer tubular section, for example Figure 4A and 4B As shown, the crush grooves 22 are arranged on opposite sides of the interior volume 36 for lateral impact forces to cause the reinforcement insert 20 to laterally deform inward at the crush grooves 22 to provide an accordion-style lateral crush pattern. In other examples, a single crush groove can be provided, or additional crush grooves can be utilized. The crush grooves can be arranged at the upper and lower walls of the outer tubular section, while no crush grooves are provided in the other tubular sections, or alternatively, the crush grooves can be arranged at the upper and lower walls of the inner tubular section, while no crush grooves are provided in the outer tubular section, for example

[0035] As shown, the crush grooves 22 are arranged on opposite sides of the interior volume 36 for lateral impact forces to cause the reinforcement insert 20 to laterally deform inward at the crush grooves 22 to provide an accordion-style lateral crush pattern. In other examples, a single crush groove can be provided, or additional crush grooves can be utilized. The crush grooves can be arranged at the upper and lower walls of the outer tubular section, while no crush grooves are provided in the other tubular sections, or alternatively, the crush grooves can be arranged at the upper and lower walls of the inner tubular section, while no crush grooves are provided in the outer tubular section, for example Figure 4A and 4BFurther shown, the outer tubular section 42 of the reinforcement insert 20 has an outer wall 48 that is integrally interconnected between the upper wall 38 and the lower wall 40 of the reinforcement insert 20. The outer wall 48 faces and contacts the outermost wall section 32 of the outer rocker member 16. Similarly, the inner tubular section 44 has an inner wall 50 that is integrally interconnected between the upper wall 38 and the lower wall 40 of the reinforcement insert 20. The inner wall 50 faces and contacts the innermost wall section 26 of the inner rocker member 14. Thus, the reinforcement insert can have a lateral width between the inner and outer walls that is sized to closely fit or occupy the distance between the inner and outer rocker members, e.g. Figure 4A and 4B as shown. However, in other examples, the reinforcement insert can only closely fit to one of the inner and outer rocker members, and have a gap on the other side, or alternatively can be designed to have a gap on both sides so as to float in the space between the inner and outer rocker members. Also, while the reinforcement insert 20 shown in Figure 4A and 4B is spaced apart from the upper wall sections 24, 30 and the lower wall sections 28, 34, it is contemplated that the spacing can be reduced or substantially eliminated due to the ability of the crush control features to inwardly deform under lateral impact forces at the outer side of the rocker assembly, e.g., to deform in an accordion shape within the outer structure of the rocker assembly.

[0036] To form the tubular insert 20 shown in Figures 3-4B a metal sheet is roll formed to have an outer tubular section 42 and an inner tubular section 44 that are laterally adjacent to each other, which share a common central wall 46. The outer sections of the metal sheet that form the two adjacent tubular sections extend from opposite sides of the central section of the metal sheet that forms the common central wall 46. As oriented in Figures 3-4B , the two adjacent tubular sections 14, 16 are defined on opposite sides of the common central wall 46 by upper walls 52, 54, lower walls 56, 58, an outer wall 48 and an inner wall 50. Crush notches 22 are roll formed into the metal sheet at the upper walls 52, 54 and the lower walls 56, 58. The crush notches 22 have a width that is about 10-40% of the width of the respective wall section (or more preferably about 20-30% of the width of the wall), and have a depth that is about equal to the width dimension. As shown in Figure 4A and 4B , the crush notches 20 shown are semi-circular. It is also contemplated that the depth and dimensions of the crush notches can be made shallower, deeper, wider, narrower, or otherwise modified to achieve the desired crush characteristics.

[0037] To form the tubular insert 20 shown in Figure 4A and 4BThe metal sheet of the reinforcement insert in FIG. 1 is a steel material, such as an advanced high strength steel (AHSS), having a thickness of 0.8 mm to 1.4 mm or approximately between 1 mm and 1.5 mm. Further, the sheet 12 can have a tensile strength of about 800 to 2000 MPa (i.e., about 120 to 290 ksi). It is also contemplated that the reinforcement insert can be made of sheets having different thicknesses and can be made of one or a combination of different materials, such as steel, aluminum, and / or composite materials.

[0038] To maintain the roll-formed sheet in the tubular shape of the reinforcement insert 20, one edge 60a of the sheet is connected by welding to the lower end of the center wall 46 and the other edge 60b is connected by welding to the upper wall 52 proximate the upper end of the center wall 46. The upper and lower walls 52, 54 and 56, 58 of adjacent tubular sections 42, 44 are substantially aligned with each other to form the respective upper and lower walls 38 and 40 of the reinforcement insert. Further, the outer and inner walls 28 and 30 are substantially parallel to each other and substantially perpendicular to the common center wall 18 and substantially perpendicular to the upper and lower walls 20, 22, 24, 26. Additional examples of reinforcement inserts can take on various shapes and orientations from those shown in FIGS. 1-3 and can include alternative dimensional proportions, such as for different applications of the insert. Figure 4A and Figure 4B

[0039] The reinforcement insert can be supported and / or attached within the exterior structure in various ways. For example, a series of brackets 62 Figure 4B are connected between the upper and lower flanges 14a, 14b, 16a, 16b of the outer rocker member 14 and the inner rocker member 16, which brackets are spaced along the length of the reinforcement insert. As shown in FIG. 4, the brackets 62 have an L-shape with an inner portion 64 connected to the upper and lower walls 38, 40 and an outer portion 66 connected by welding to the upper and lower flanges 14a, 14b, 16a, 16b between the outer and inner rocker members 14, 16 to support the reinforcement insert 20 in the hollow space 18. In other examples, the reinforcement insert can also or alternatively be connected to the inner surface of the outer or inner rocker member, such as by welding, fasteners, and / or adhesive. Figure 4B

[0040] Referring to FIG. 5, Figures 5-6B the reinforcement insert 120 is disposed within the hollow space 118 extending longitudinally along the entire inner rocker member 114 and along a portion of the outer rocker member 116. The extruded channel 122 of the reinforcement insert 120 is integrally formed in the reinforcement insert 120 and extends uniformly along the length of the reinforcement insert 120. As shown in FIG. 5, the reinforcement insert 120 is connected to the inner surface of the outer rocker member 116 by welding, such as by spot welding, and is connected to the inner surface of the inner rocker member 114 by welding, such as by spot welding. Figure 6A and 6B ​​As shown, the reinforcing insert 120 is longitudinally extruded, for example, from an aluminum alloy, to have an outer tubular section 142 and an inner tubular section 144 sharing a common wall 146, which is integrally interconnected between the upper wall 138 and the lower wall 140 of the reinforcing insert 120. The upper wall 138 and the lower wall 140 are adjacent to opposite sides of the internal volume 136 of the reinforcing insert 120 and are arranged in planar parallel alignment with each other. Extrusion grooves 122 are extruded into the upper wall 138 and the lower wall 140 to extend into the corresponding tubular shape of the internal volume 136 of the reinforcing insert 120. Figure 6A and 6B The extrusion groove 122 shown has a V-shape to facilitate the initiation of lateral extrusion of the reinforcing insert at the extrusion groove. The extrusion groove 122 is arranged on opposite sides of the internal volume 136 for lateral impact forces to cause the reinforcing insert 120 to deform laterally inward at the extrusion groove 122, thereby providing an accordion-like lateral extrusion pattern.

[0041] like Figure 6A and 6B As shown, the reinforcing insert 120 includes an outer tubular section 142 and an inner tubular section 144, which are integrally formed together and arranged laterally adjacent to each other. The compression groove 122 is mirror-image across the internal volume 136 of the outer tubular section 142 and the inner tubular section 144, so as to be vertically aligned with each other. Similarly, as... Figure 6A and 6B As shown, the outer tubular section 142 of the reinforcing insert 120 has an outer wall 148 integrally interconnected between the upper wall 138 and the lower wall 140 of the reinforcing insert 120. The outer wall 148 faces and contacts the outermost wall section 132 of the outer sill member 116. Similarly, the inner tubular section 144 has an inner wall 150 integrally interconnected between the upper wall 138 and the lower wall 140 of the reinforcing insert 120. The inner wall 150 faces and contacts the innermost wall section 126 of the inner sill member 114.

[0042] To support the reinforcing insert 120 within the external structure 112, a series of brackets 162 are attached between the upper and lower flanges 114a, 114b, 116a, 116b of the outer sill member and the inner sill members 114, 116. Figure 6B As shown, the bracket 162 has an L-shape, with an inner portion 164 connected to the upper wall 138 and the lower wall 140, and an outer portion 166 connected between upper and lower flanges 114a, 114b, 116a, 116b to support the reinforcing insert 120 in the hollow space 118. The connection between the bracket and the reinforcing insert and the external structure can be accomplished using welding, fasteners, adhesives, and / or material intermediates, for example, in a manner to prevent electrochemical corrosion.

[0043] Further, in some embodiments, the reinforcement insert can include a flange that is attached between the upper flanges of the outer rocker member and the inner rocker member, with the flange being attached to the exterior structure of the rocker panel assembly to support the tubular insert in the hollow space of the exterior structure. As Figure 8A As shown, the reinforcement insert 220 includes an upper flange portion 270 that extends integrally upward from the crushable insert portion 268, and a lower flange portion 272 that extends integrally downward from the crushable insert portion 268. The upper flange portion 270 and the lower flange portion 272 are attached between respective upper and lower flanges 214a, 214b, 216a, 216b of the edges or face panels 212, 214 of the inner rocker member 214 and the outer rocker member 216 to secure the reinforcement insert 220 relative to the inner rocker member 214 and the outer rocker member 216. For example, the flange portions are spot welded between the first and second face panels 214, 216, although alternative welding methods or different attachment means, such as adhesives, mechanical fasteners, or combinations thereof, can be used. In other embodiments, the integral flanges of the reinforcement insert can also be used for attachment to the vehicle frame or other component parts.

[0044] With further reference to Figures 7-8A The reinforcement insert 220 is roll formed from sheet metal to provide the crushable insert portion 268 and the upper and lower flange portions 270, 272 as integral parts of the sheet metal, extending longitudinally continuously along the length of the reinforcement insert 220. The upper flange portion 270 and the lower flange portion 272 of the reinforcement insert 220 are provided at edge portions of the sheet metal. As shown, Figure 8A The wall segments of the crushable insert portion 268 include a common center wall 246 that divides two adjacent tubular segments 214, 216, upper walls 252, 254, lower walls 256, 258, an outer wall 248, and an inner wall 250. The crush grooves 222 are roll formed into the sheet metal at the upper walls 252, 254 and the lower walls 256, 258. After forming welds along the upper and lower walls to close the adjacent tubular segments 242, 244, the upper flange portion 270 extends upward from the upper wall 254, and the lower flange portion 272 extends downward from the lower wall 256.

[0045] As Figure 8A Further shown, the intermediate portion of the outer rocker member 216 has an upper wall segment 230 that is formed in a stepped shape and is integrally interconnected with an outermost wall segment 232 that is generally planar and vertically oriented. The outermost wall segment 232 extends downward to be integrally interconnected with a lower wall segment 234 that is generally planar and slightly angled from horizontal. The stepped shape of the upper wall segment 230 reduces the distance through the hollow interior 218 between the inner rocker member 214 and the outer rocker member 216 at the upper portion of the inner rocker member 214.

[0046] Also for purposes of this disclosure, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", "inside", "outside", and derivatives thereof shall relate to the Figure 1 The terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", "inside", "outside", and derivatives thereof shall relate to the orientation as shown in the figures. However, it is to be understood that various alternative configurations can be provided without departing from the spirit of the present disclosure. It will be further appreciated that certain devices and methods described in the specification can be optional depending on the particular implementation. The specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

[0047] Changes and modifications to the specifically described embodiments can be carried out without departing from the principles of the present disclosure, which is defined by the scope of the claims depending on the patent law. The present disclosure has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the present disclosure can be implemented in a different manner than was specifically described.

Claims

1. A vehicle rocker assembly, comprising: an outer rocker member; an inner rocker member attached lengthwise along the outer rocker member to define a hollow space between the inner rocker member and the outer rocker member; and a tubular insert disposed in and extending lengthwise along the hollow space, the tubular insert having upper and lower walls bounding opposite sides of an interior volume of the tubular insert, the tubular insert including a metal plate integrally forming a closed tubular section that surrounds the interior volume to form the upper and lower walls of the tubular insert, the closed tubular section having an interior wall extending along the tubular insert that divides the interior volume; wherein at least one of the upper or lower walls of the tubular insert has an extruded groove extending lengthwise along the tubular insert, and wherein the tubular insert is configured to induce lateral deformation of the tubular insert at the extruded groove for a lateral impact force at the outer rocker member.

2. The vehicle rocker assembly of claim 1, wherein the extruded groove projects into the interior volume of the tubular insert.

3. The vehicle rocker assembly of claim 1, wherein the upper and lower walls each include the extruded groove disposed along the respective upper and lower walls at opposite sides of the interior volume.

4. The vehicle rocker assembly of claim 3, wherein the extruded grooves are vertically aligned across the interior volume of the tubular insert.

5. The vehicle rocker assembly of claim 3, wherein the upper and lower walls of the tubular insert are disposed in planar parallel alignment with each other.

6. The vehicle rocker assembly of claim 1, wherein the closed tubular section includes an outer tubular section and an inner tubular section integrally formed together and sharing the interior wall to be disposed laterally adjacent to each other.

7. The vehicle rocker assembly of claim 6, wherein the interior wall extends vertically between the upper and lower walls of the tubular insert.

8. The vehicle rocker assembly of claim 6, wherein the outer tubular section includes an outer wall attached at the outer rocker member.

9. The vehicle rocker assembly of claim 6, wherein the inner and outer tubular sections each include an extruded groove disposed along respective upper and lower walls of the inner and outer tubular sections.

10. The vehicle rocker assembly of claim 1, wherein the tubular insert includes outer tubular sections and inner tubular sections, and wherein the interior wall forms a portion of each of the outer and inner tubular sections.

11. A vehicle rocker assembly, comprising: a rocker structure having an outer rocker member attached along an inner rocker member; ​ a reinforcement insert arranged in a hollow interior between the outer rocker member and the inner rocker member, the reinforcement insert comprising a sheet metal that integrally forms a closed tubular section having an outer tubular section and an inner tubular section integrally formed together and arranged laterally adjacent to each other, the closed tubular section having a common center wall separating the outer tubular section and the inner tubular section; and an extrusion control feature integrally arranged at a wall of the reinforcement insert and extending longitudinally along a length of the reinforcement insert, wherein the extrusion control feature is configured for a lateral impact force at the outer rocker member to laterally deform the reinforcement insert in an accordion-like extrusion.

12. The vehicle rocker assembly of claim 11, wherein the common center wall of the reinforcement insert extends vertically between an upper wall and a lower wall of the reinforcement insert.

13. The vehicle rocker assembly of claim 12, wherein the extrusion control feature includes a first extrusion groove arranged at the upper wall of the reinforcement insert and a second extrusion groove arranged at the lower wall of the reinforcement insert.

14. The vehicle rocker assembly of claim 13, wherein the first and second extrusion grooves are mirrored on an interior volume of the reinforcement insert.

15. The vehicle rocker assembly of claim 13, wherein the first and second extrusion grooves are vertically aligned on the interior volume of the reinforcement insert.

16. The vehicle rocker assembly of claim 11, wherein the tubular insert is secured at an inner surface of the rocker structure by at least one of welding, fasteners, or adhesive.

17. A vehicle rocker assembly, comprising: an outer rocker member; an inner rocker member attached longitudinally along the outer rocker member to define a hollow space between the inner rocker member and the outer rocker member; and a tubular insert arranged in and extending longitudinally along the hollow space, the tubular insert comprising a sheet metal that integrally forms a closed tubular section, the closed tubular section surrounding an interior volume to form an upper wall and a lower wall of the tubular insert, the closed tubular section including an outer tubular section and an inner tubular section integrally formed together and separated by a common center wall extending along the tubular insert, wherein at least one of the outer tubular section or the inner tubular section includes an upper extrusion groove and a lower extrusion groove arranged at respective upper and lower walls of the at least one of the outer tubular section or the inner tubular section, wherein the upper and lower extrusion grooves extend longitudinally along the tubular insert and are configured for a lateral impact force at the outer rocker member to induce lateral deformation of the tubular insert.

18. The vehicle rocker panel assembly of claim 17, wherein the upper extruded recess and the lower extruded recess are vertically aligned on respective ones of the outer tubular section and the inner tubular section of the tubular insert.

19. The vehicle rocker panel assembly of claim 17, wherein the upper wall and the lower wall of the tubular insert are arranged in planar parallel alignment with one another, and wherein the common central wall extends vertically between the upper wall and the lower wall of the tubular insert.

20. A vehicle rocker panel assembly, comprising: an outer rocker panel member; an inner rocker panel member attached longitudinally along the outer rocker panel member to define a hollow space along and between the inner rocker panel member and the outer rocker panel member; a tubular insert arranged in and extending longitudinally along the hollow space, the tubular insert having upper and lower walls bounding opposite sides of an interior volume of the tubular insert, the tubular insert comprising a sheet metal that integrally forms a closed tubular section that surrounds the interior volume to form the upper and lower walls of the tubular insert, the closed tubular section having an interior wall extending along the tubular insert that divides the interior volume; and wherein at least one of the upper or lower walls of the tubular insert has an extruded recess extending longitudinally along the tubular insert, the tubular insert being configured for a lateral impact force at the outer rocker panel member to cause the tubular insert to laterally deform at the extruded recess, thereby providing an accordion-type lateral extrusion to at least partially absorb the lateral impact force.

21. The vehicle rocker panel assembly of claim 20, wherein the extruded recess projects into the interior volume of the tubular insert.

22. The vehicle rocker panel assembly of claim 20, wherein a pair of extruded recesses are arranged along respective upper and lower walls at opposite sides of the interior volume.

23. The vehicle rocker panel assembly of claim 22, wherein the pair of extruded recesses mirror across the interior volume.

24. The vehicle rocker panel assembly of claim 22, wherein the extruded recesses are vertically aligned across the interior volume of the tubular insert.

25. The vehicle rocker panel assembly of claim 20, wherein the extruded recesses of the tubular insert are configured to deform simultaneously under the lateral impact force at the outer rocker panel member.

26. The vehicle rocker panel assembly of claim 22, wherein the upper wall and the lower wall of the tubular insert are arranged in planar parallel alignment with one another and are spaced apart from the outer rocker panel member and the inner rocker panel member.

27. The vehicle rocker panel assembly of claim 20, wherein the closed tubular section comprises an outer tubular section and an inner tubular section that are integrally formed together and share the interior wall to be arranged laterally adjacent to one another.

28. The vehicle footwell assembly of claim 27, wherein the interior wall extends vertically between the upper wall and the lower wall of the tubular insert.

29. The vehicle footwell assembly of claim 20, wherein the tubular insert includes an outer tubular section having an outer wall facing the outer rocker member and integrally interconnected between the upper wall and the lower wall of the tubular insert.

30. The vehicle footwell assembly of claim 20, further comprising a cradle attached between upper flanges of the outer rocker member and the inner rocker member, the cradle being attached to the tubular insert and supporting the tubular insert in the hollow space.

31. The vehicle footwell assembly of claim 20, wherein the tubular insert includes a flange attached between upper flanges of the outer rocker member and the inner rocker member, the flange supporting the tubular insert in the hollow space.

32. The vehicle footwell assembly of claim 20, wherein the tubular insert is secured at an inner surface of the outer rocker member or the inner rocker member by at least one of welding, fasteners, or adhesive.

33. The vehicle footwell assembly of claim 20, wherein the tubular insert includes an outer tubular section and an inner tubular section that share the interior wall, and wherein the outer tubular section and the inner tubular section are disposed laterally adjacent to each other.

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