Vehicle stiffening beam

Abstract

A stiffening beam (12) for a vehicle (100) has an outer beam (20) and an inner beam (22). The outer beam (20) transversely spans between crush boxes (14) of the vehicle (100). The outer beam (20) forms an elongated hollow body having a front wall (30) and a rear wall (32) extending along the length of the stiffening beam (12). The inner beam (22) is disposed along a middle section (24) of the outer beam (20). The inner beam (22) further includes an upper wall (34) and a lower wall (36) each extending between the front wall (30) and the rear wall (32) of the outer beam (20). The front wall (30) and the rear wall (32) can include at least one rib (46, 47) extending along the length of the outer beam (20).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority under 35 U.S.C. §119(e) to U.S. Provisional Application Serial No. 63 / 382,286, filed on November 3, 2022, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure generally relates to reinforcement beams for vehicles, such as bumper reinforcement beams for bumper assemblies, subassemblies, and components thereof. Background Art

[0004] The vehicle bumper system generally includes at least one reinforcing beam across the front or rear end of the vehicle. The main reinforcing beam is generally supported by a crush box attached to the frame structure. The vehicle bumper system is subjected to strict collision energy management and high-speed and low-speed impact collision absorption tests, such as to meet mandatory government regulations and insurance certification. For example, the collision requirements and regulations for the bumper system are provided by the Federal Motor Vehicle Safety Standards (US FMVSS), the Insurance Institute for Highway Safety (IIHS), the National Highway Traffic Safety Administration (NHTSA), the European EC E42 consumer legislation, and Asian pedestrian protection for the thigh and calf. The bumper system is also designed to maximize the strength-to-weight ratio in an effort to minimize the gross vehicle weight while balancing the cost of the associated bumper system components. Summary of the invention

[0005] The present disclosure provides a reinforcement beam for a vehicle, the reinforcement beam being used to receive and absorb collision loads transmitted by a vehicle collision, such as an embodiment of a bumper reinforcement beam supported by a crush box at a vehicle frame. The bumper reinforcement beam includes an outer beam component and an inner beam component, the outer beam component being configured to span laterally between the crush boxes, the inner beam component reinforcing a center or middle section of the outer beam component so that the inner beam component is omitted at the end sections of the outer beam, which are originally supported to a greater extent by the crush boxes. The outer beam component has an elongated hollow body formed of sheet metal, such as a front plate and a rear plate attached together along respective upper and lower flanges. The inner beam reinforces the hollow region between the front and rear walls of the outer beam by providing an upper wall and a lower wall extending between the front and rear walls. The inner beam may have a greater bending strength than the outer beam, such as due to forming the inner beam with a sheet metal having a greater thickness or tensile strength, etc.

[0006] One aspect of the present disclosure provides a bumper reinforcement beam configured to be supported by a crush box at a vehicle frame. The bumper reinforcement beam includes an outer beam and an inner beam. The outer beam has an elongated hollow body formed of a metal sheet and configured to span transversely between the crush boxes. The hollow body includes a front wall and a rear wall extending along a length defined between a first end and a second end of the hollow body. The inner beam is disposed along a middle section of the outer beam, wherein the inner beam has an upper wall and a lower wall, each of which extends between the front wall and the rear wall of the outer beam.

[0007] The front wall and the rear wall of the outer beam may include at least one rib extending along the length of the outer beam. The length of the inner beam between its opposite ends may be less than one-half the length of the outer beam. End sections of the outer beam disposed at opposite ends of the central section may be free of the inner beam. In some aspects, the inner beam may be formed of a sheet metal having a thickness greater than that of the sheet metal of the outer beam, such as about twice the thickness of the sheet metal of the outer beam.

[0008] The inner beam may have a middle portion or connecting wall interconnected between the upper wall and the lower wall to define a channel along the inner beam. The middle portion may have a groove formed along the front surface of the inner beam. The middle portion of the inner beam may be coupled to the front wall of the outer beam.

[0009] The upper wall and the lower wall of the inner beam can divide the internal volume of the hollow body to form a plurality of elongated hollow areas. In some examples, the inner beam has a rear flange extending integrally from the upper wall and the lower wall. The rear flange can be attached to the rear wall of the outer beam. The upper wall and the lower wall of the inner beam can extend rearward at an angle of less than 40 degrees relative to the normal of the plane extent of the front wall. In some aspects, the upper wall of the inner beam extends rearward and upward at an angle of less than 20 degrees relative to the normal of the plane extent of the front wall. In some aspects, the lower wall of the inner beam extends rearward and downward at an angle of less than 20 degrees relative to the normal of the plane extent of the front wall.

[0010] The front wall of the outer beam may have one or more ribs extending along the length of the outer beam. In some examples, the outer beam includes a front piece and a rear piece, the front piece having a front wall and the rear piece having a rear wall. The front piece and the rear piece may be attached together along respective upper and lower flanges to enclose the hollow interior of the outer beam. In some examples, the upper and lower flanges are each attached together via welding. The upper flange of the front piece and the upper flange of the rear piece may protrude upward from the hollow interior of the hollow body. The lower flange of the front piece and the lower flange of the rear piece may protrude downward from the hollow interior of the hollow body.

[0011] The front and rear pieces of the outer beam may each be formed from separate metal sheets. In some aspects, the rear piece of the outer beam includes an upper wall and a lower wall that together with the rear wall define a C-shaped cross-section. The rear surface of the rear piece may include an attachment surface suitable for attachment to a crush box.

[0012] Another aspect of the present disclosure provides a bumper reinforcement beam configured to be supported by a crush box at a vehicle frame. The bumper reinforcement beam includes a front beam member and a rear beam member, the front beam member having a front wall and the rear beam member having a rear wall. The upper edge and the lower edge of the rear beam member are attached along the corresponding upper edge and the lower edge of the front beam member to define an elongated hollow body having a length configured to span between the crush boxes. An inner beam member is attached between the front beam member and the rear beam member and includes an upper wall and a lower wall extending between the front wall and the rear wall. The length of the inner beam member is less than one-half of the length of the elongated hollow body.

[0013] Yet another aspect of the present disclosure provides a reinforcement beam for a vehicle, wherein the reinforcement beam has an outer beam member and an inner beam member. The outer beam member includes an outer side wall, and the inner beam member includes an inner side wall. The inner beam member also includes an upper flange and a lower flange, which are attached along respective upper and lower edges of the outer beam member to define an elongated hollow body having a length defined between opposite ends of the outer beam member. The inner beam member is attached between the outer beam member and the inner beam member and includes a C-shaped cross-section defining an upper shear wall and a lower shear wall, each of which extends between the outer side wall and the inner side wall. The length of the inner beam member is less than one-half of the length of the elongated hollow body.

[0014] Each of the above-mentioned independent aspects of the present disclosure, as well as those aspects described in the detailed description below, may include any of the features, options and possibilities set forth in the present disclosure and the drawings, including those under other independent aspects, and may also include any combination of any of the features, options and possibilities set forth in the present disclosure and the drawings.

[0015] The details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the following description. Other aspects, advantages, objects and features will become apparent from the following description read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a side elevation view of a vehicle having a bumper assembly including a reinforcement beam.

[0017] Figure 1A yes Figure 1 A perspective view of a vehicle showing various additional reinforcement beams.

[0018] Figure 2 yes Figure 1 Side elevation view of the reinforcement beam and supporting crush box.

[0019] Figure 3 yes Figure 2 Front elevation view of the reinforcement beam.

[0020] Figure 4A yes Figure 2 An exploded perspective view of the reinforcement beam is shown.

[0021] Figure 4B is an exploded perspective view of an additional example of a reinforcing beam.

[0022] Figure 5 yes Figure 2 Side elevation view of the reinforcement beam.

[0023] Figure 6 yes Figure 2 Exploded side view of the reinforcement beam.

[0024] Figure 7 It is shown by a dotted line Figure 8 A graph showing experimental test results of a reinforcement beam compared to existing reinforcement beams under crash load conditions.

[0025] Figures 8 to 19 is a cross-sectional side view of an example of a reinforcement beam taken at a mid-section of the length of the reinforcement beam.

[0026] Fig. 20 is a perspective view of an additional example of a reinforcing beam.

[0027] Fig.21 is a perspective view of an additional example of a reinforcing beam.

[0028] Fig. 22 yes Fig.21 Exploded perspective view of the reinforcement beam.

[0029] Fig.23 yes Fig.21 Exploded side view of the reinforcement beam.

[0030] Fig.24 is a perspective view of an additional example of a reinforcing beam.

[0031] Fig.25 yes Fig.24 Exploded perspective view of the reinforcement beam.

[0032] Fig.26 yes Fig.24 Exploded side view of the reinforcement beam.

[0033] Like reference numerals refer to like parts throughout the drawings. DETAILED DESCRIPTION

[0034] A reinforcement beam for a vehicle is disclosed in various embodiments herein as a collision energy absorption and management device that is used in conjunction with other vehicle components to absorb and manage collision loads and energy while minimizing damage and intrusion during a collision with the vehicle. For example, a reinforcement beam may be employed at a bumper assembly attached to a vehicle frame, wherein the reinforcement beam is a transverse body structure supported by a crush box. In some cases, a vehicle bumper assembly may have increased front-end stiffness and collision energy absorption requirements, such as for electric vehicles or rear-engined vehicles that have greater vehicle mass and a front end that may be more susceptible to collision intrusion. While it is well known that a bumper reinforcement beam with increased mass can meet the increased stiffness requirements, the increased mass generally increases vehicle cost while also reducing mileage and / or fuel efficiency.

[0035] The reinforced beam 12 of the present disclosure includes an outer beam member 20 and an inner beam member 22, the inner beam member reinforcing the middle section 24 ( Figure 3 ). The outer beam member 20 has an elongated hollow body, which may be formed of a metal sheet. Figure 4A As shown, the outer beam member 20 includes a front member 26 and a rear member 28 that can be attached together along their respective upper edges 27 and lower edges 29, such as along defined upper and lower flanges. The inner beam member 22 strengthens the hollow region between the front wall 30 and the rear wall 32 of the outer beam member 20 by providing an upper wall 34 and a lower wall 36 that each extend between the front wall 30 and the rear wall 32.

[0036] As described herein, references to the front, rear, and other directional derivative terms of this example of a reinforcement beam are made with reference to its use in the front bumper assembly ( Figure 1 ) and its relative position on the associated vehicle 100. However, it should be understood that the reinforcement beam disclosed herein can also be used in the rear bumper assembly 13 or the side frame structure 15 ( Figure 1A ) such as rocker beams or battery tray side beams, and other conceivable uses on the vehicle structure or subassembly to absorb and manage collision loads and energy.

[0037] Referring now to the drawings and illustrative examples depicted therein, such as Figure 1 The bumper assembly 10 for a vehicle 100 is shown having a bumper reinforcement beam 12 supported by crush boxes 14 attached to the bumper reinforcement beam 12 at intervals substantially equal to the center of the bumper reinforcement beam 12. The crush boxes 14 of the bumper assembly 10 are each mounted to the ends or ends of a frame rail 16 or other supporting portion of the frame to position the bumper reinforcement beam 12 so that it spans transversely (in the width direction of the vehicle) over the front end of the vehicle 100. Figure 1As shown, the bumper assembly 10 is mounted at the front end of a vehicle 100, which may be a passenger car or other type of motor vehicle, such as a car, truck, bus, van, or sport utility vehicle. The crush box 14 is used to support the bumper reinforcement beam 12 at the frame 16 and to direct and absorb the collision load 18 received from the supported bumper reinforcement beam 12 (in the longitudinal or x-direction relative to the vehicle) through the crush box 14 to the attached frame 16. It is also contemplated that the bumper assembly and other embodiments thereof may be used or otherwise incorporated into the rear end or other area of ​​the vehicle. Figure 1A 1 , wherein various reinforcement beams for vehicle 100 are depicted in phantom. Embodiments of the bumper assembly may be incorporated into other vehicle structural members such as those illustrated, including rear bumpers, roof rails, A-pillars, and B-pillars.

[0038] For example, in Figure 2 As shown in FIG. 1 , a bumper reinforcement beam 12 and a crush box 14 are illustrated. The crush box 14 is formed as a thin-walled hollow structure, which is a fragile structure designed to be compressed to absorb the collision energy received at the bumper reinforcement beam 12. The bumper assembly 10 may include one or more attachment plates 17, which are located between the crush box 14 and the bumper reinforcement beam 12 or between the crush box 14 and the frame member 16 ( Figure 1 ), between or both. The one or more attachment plates 17 may include a distribution of holes for attachment to the bumper reinforcement beam 12 or the frame member 16 using threads or similar fasteners (such as bolts, rivets, etc.). The crush box 14 may be welded to the one or more attachment plates 17. Alternatively, the crush box 14 may be welded directly to the bumper reinforcement beam 12, or to the frame member 16, or to both.

[0039] like Figure 2 and Figure 3 As further shown in FIG. 1 , the inner beam member 22 of the bumper reinforcement beam 12 reinforces the middle section 24 of the outer beam member 20. The middle section 24 may include a central section of the outer beam member 20, such as Figure 3 In other examples, the middle section 24 may be eccentric along the length of the outer beam member 20. Figure 3As illustrated, the intermediate section 24 may include one position along the length of the outer beam member 20, so that the bumper assembly 10 includes one inner beam member 22. In other examples, more than one intermediate section 24 and more than one inner beam member 22 may be included along the length of the outer beam member 20. By adding more than one inner beam member 22, the beam assembly 10 may drive the buckling point to a specific location without the need for additional support of the inner beam member 22. The length of the inner beam member 22 between its opposite ends is less than one-half of the length of the outer beam member 22. For example, the length of the outer beam member may be in a range between about 800 mm and 1,600 mm, or in a range between 1,000 mm and 1,250 mm, such as about 1,200 mm, and the length of the inner beam member may be in a range between about 300 mm and 600 mm, such as about 400 mm. In some examples, such as in bumper members extended for small overlap collision testing, the outer beam member may have a length in a range between 1,500 mm and 1,600 mm. These ranges are inclusive of the respective endpoints.

[0040] like Figure 3 As shown, the side end sections 38a, 38b of the outer beam member disposed at opposite ends of the center section 24 are free of the inner beam member 22. However, due to the support of the outer beam member 20 provided by the crush box 14 at the side end sections 38a, 38b, the side end sections 38a, 38b are subjected to less bending stress than the center section 24. Therefore, the reinforcement provided by the inner beam member 22 is not provided at the side end sections 38a, 38b. It should be understood that in additional examples, the reinforcement beam can be longer and the collision location can be changed from the center section, such as in other embodiments on the vehicle.

[0041] like Figure 4A As illustrated, the bumper reinforcement beam 12 includes a generally straight shape along the length of the beam 12. Each of the beam components forming the reinforcement beam 12 has a corresponding straight shape to securely fit the components together along the length of the beam. Figure 4B In other examples shown, the bumper reinforcement beam 12 includes a bend or curvature formed along the length of the beam 12. Such a bend or curvature generally allows the beam to conform to the packaging space allowed by the vehicle design. The bend may have a consistent radius of curvature along the length of the bumper reinforcement beam, such as Figure 4B As shown, or in additional examples, the curved shape may have varying radii of curvature at different sections of the length, such as having a greater curvature (and in fact a smaller radius of curvature) at the side end sections of the beam. Figure 4B As further illustrated, each of the beam components forming the bumper reinforcement beam 12 has a corresponding curved shape to securely fit the components together over the length of the reinforcement beam. Figure 4BThe corresponding curved shapes between the beam members shown are provided by the same or substantially similar radius of curvature of each beam member.

[0042] like Figure 5 and Figure 6 As illustrated in the example of FIG, the outer beam member 20 has an elongated hollow body formed of sheet metal, such as a front plate or front piece 26 and a rear plate or rear piece 28 attached together. In other words, the front piece 26 of the outer beam member 20 is the outer side beam member 26, and the rear piece 28 is the inner side beam member 28. The front piece 26 and the rear piece 28 are coupled together at their respective upper flanges 40a, 42a and lower flanges 40b, 42b. The front piece 26 and the rear piece 28 can be coupled directly or indirectly, for example, by mechanical bonding (such as via welding adhesives, etc.). As shown in FIG. Figure 5 As shown, the front piece 26 has an upper flange 40a extending upwardly beyond the hollow interior area 44 defined by the outer beam member 20 and a lower flange 40b extending downwardly beyond the hollow interior area 44 defined by the outer beam member 20. The upper flange 40a and the lower flange 40b of the front piece 26 extend vertically in a planar extension of the front wall 30 of the front piece.

[0043] Also like Figure 5 As shown, the rear piece 28 has an upper flange 42a extending upwardly beyond the hollow interior area 44 defined by the outer beam member 20 and a lower flange 42b extending downwardly beyond the hollow interior area 44 defined by the outer beam member 20. The upper flange 42a and the lower flange 42b of the front piece 26 also extend vertically so as to position the front mating surface to receive the rear mating surface of the upper flange 40a and the lower flange 40b of the front piece 26. The upper flanges 40a, 42a and the lower flanges 40b, 42b are joined together to form a flange connection in which the plates overlap at the upper and lower front corners of the outer beam member 20, protruding vertically above and below the hollow interior area 44 enclosed by the outer beam member 20.

[0044] like Figure 5 As shown, the rear member 28 of the outer beam member 20 includes an upper wall 48 and a lower wall 50, which together with the rear wall 32 define a C-shaped cross section. The upper flange 42a of the rear member 28 extends upward from the front portion of the upper wall 48. Similarly, the lower flange 42b of the rear member 28 extends downward from the front portion of the lower wall 50. Therefore, Figure 5 The example shown provides a depth D for the outer beam member 20 of the entire reinforcing beam 12, which is defined by the length of the upper wall 48 and the lower wall 50 of the outer beam member 20. The depth D of the cross section is constant along the length of the reinforcing beam 12 and is generally proportional to other features. In the example shown, the depth is about 40 mm, and in additional examples, the depth may be between 50 mm and 70 mm, or more or less. Figure 5 and Figure 6The rear wall 32 of the outer beam member 20 is shown with two rear ribs 47 extending along the length of the outer beam member. In additional examples, there may be more or fewer rear ribs, and the rear ribs may have different shapes, sizes, and locations on the rear wall. In addition, the rear ribs 47 have a vertical height on the rear face and a forward depth from the rear face of the rear wall 32 that is configured to allow the sheet material to be formed inwardly into a generally curved shape without exceeding the allowable curvature (minimum possible bend radius) of the sheet material without failure. The rear ribs 47 provide additional rigidity to the rear wall 32. In other examples, the rear wall 32 has no rear ribs 47 ( Figure 8 ). For example, the beam assembly may have a height of less than 80 mm. In some cases, the rear rib 47 may not be provided.

[0045] Again, referring to the previous item 26, Figure 5 and Figure 6 The front wall 30 of the outer beam member 20 is shown with two front ribs 46 extending along the length of the outer beam member. In additional examples, there may be more or fewer front ribs, and the front ribs may have different shapes, sizes and locations on the front wall. In addition, the front ribs 46 have a vertical height on the front surface and a rearward depth from the front face of the front wall 30 that is configured to allow the sheet material to be formed inwardly into a generally curved shape without exceeding the allowable curvature (minimum possible bending radius) of the sheet material without failure. The front ribs 46 provide additional rigidity to the front wall.

[0046] The sheet metal of the outer beam component may include any metal or metal alloy having desired properties such as stiffness, tensile strength, etc. For example, the material may include aluminum or steel, such as high strength or ultra-high strength steel, and combinations of other related metals in different alloys. For example, ultra-high strength steel is steel having an ultimate tensile strength greater than 780 MPa, or in some examples greater than 1,000 MPa. The sheet metal of the outer beam component may be formed in a variety of processes such as using cold stamping, flow forming, roll stamping, hot stamping, press brake bending, or combinations thereof.

[0047] like Figure 5 and Figure 6 As further shown, the inner beam member 22 is configured to reinforce the hollow area 44 between the front wall 30 and the rear wall 32 of the outer beam member 20 by providing an upper wall 34 and a lower wall 36 extending between the front wall 30 and the rear wall 32. The upper wall and the lower wall may also be referred to as shear walls, and may be configured to withstand axial loading of the bumper system by collision forces. The inner beam member 22 may have a greater bending strength than the outer beam member 20, such as at least in part due to forming the inner beam from a metal sheet having a greater thickness. For example, the inner beam member 22 may be formed from a different metal sheet that has a greater thickness than the outer beam, such as about twice the thickness. Figure 5In the example shown, the thickness of the metal sheet forming the inner beam member 22 is about 2 mm, and the thickness of the metal sheet forming the outer beam member 20 is about 1 mm. Therefore, the thickness of the metal sheet forming the inner beam member can be 2 times or 2.5 times or more than the thickness of the outer beam member. In additional examples, the inner beam member has a thickness greater than 1.2 mm, or greater than 1.5 mm, or greater than 1.8 mm.

[0048] like Figure 5 and Figure 6 As shown, the inner beam member 22 has an intermediate portion or connecting wall 52 that is integrally interconnected between the upper wall 34 and the lower wall 36 to define a channel or C-shape along the inner beam member 22. Figure 5 As shown, the middle portion 52 has a planar shape that abuts the inner surface of the outer beam member 20 to provide an interface surface area. The middle portion 52 of the inner beam can be attached to the front wall 30 of the outer beam member 20, such as via adhesive, welding, fasteners, etc. In addition, in some cases, the middle portion 52 of the inner beam can contact the front wall 30 of the outer beam member 20 without any fixed attachment. In additional examples, such as Figure 8 As shown, the middle portion 152 may have a groove 154 ( Figure 8 ). Like the ribs on the front wall, the grooves 154 may also provide additional rigidity and support to the front portion of the bumper reinforcement beam.

[0049] The upper wall 34 and the lower wall 36 of the inner beam member 22 can divide the hollow interior region 44 of the hollow body formed by the outer beam member 20 to form a plurality of elongated hollow regions 44', 44", 44'" ( Figure 5). In doing so, the height of the middle portion 52 of the inner beam member 22 is configured to position the ribs 46 in the front wall 30 approximately centrally above the respective upper hollow areas 44' and lower hollow areas 44'". The upper wall 34 and the lower wall 36 of the inner beam member 22 extend rearwardly at an angle α relative to the normal or perpendicular direction of the planar extent or vertical orientation of the front wall 30, or in some examples, the angle α is defined as relative to a generally horizontal plane. In some examples, the angle α is less than 40 degrees, and is preferably between -5 degrees and 20 degrees. In other examples, the angle α of the upper wall of the inner beam is less than 20 degrees relative to the normal of the planar extent of the front wall. In some examples, the angle α of the lower wall of the inner beam extends rearward and downward at an angle of less than 20 degrees relative to the normal to the plane extent of the front wall. It is also contemplated that the angle may be 12 degrees, between 10 and 12 degrees, between 8 and 12 degrees, between 5 and 15 degrees, between 0 and 15 degrees, or between -5 and 20 degrees. In examples where the rear rib 47 is positioned on the rear wall 32, the angle α may be between 8 and 12 degrees. For example, when the rear rib 47 is included, the angle α may be 10 degrees. In examples where the rear wall 32 does not have the rear rib 47, the angle α may be greater, such as 20 degrees.

[0050] In addition, if Figure 5 and Figure 6 As shown, the inner beam member 22 has rear flanges 56a, 56b extending integrally from the upper wall 34 and the lower wall 36. Figure 5 As shown, an upper rear flange 56a extends upward from the upper wall 34, and a lower rear flange 56b extends downward from the lower wall 36. In some examples, the rear flanges 56a, 56b are coupled to the rear wall 32 of the outer beam member 20, such as via welding, adhesives, fasteners, etc. In other examples, the rear flanges are not coupled to the rear wall 32. In some cases, the upper rear flange 56a and the lower rear flange 56b extend to a position adjacent to the rear rib 47 of the rear wall 32. In such a position, the rear rib 47 can be configured to retain the upper flange 56a and the lower flange 56b, such as to prevent vertical movement of the inner beam member 22 relative to the outer beam member 20 within the hollow interior area 44.

[0051] Although the thickness may be greater than the sheet metal of the outer beam member 20, the sheet metal of the inner beam member 22 may include the same metal, such as any metal or metal alloy having desired properties, such as stiffness, tensile strength, etc. For example, the material may include aluminum or steel, such as high strength or ultra-high strength steel, as well as other related metal combinations in different alloys. Furthermore, in other examples, the sheet metal of the inner beam member may include greater stiffness than the outer beam member, such as having a smaller, equal, or greater thickness. Furthermore, the sheet metal of the inner beam member 22 may also be formed in a variety of processes, such as using cold stamping, roll forming, roll stamping, hot stamping, press brake bending, or combinations thereof.

[0052] Additionally, or alternatively, the inner beam member 22 may be made in whole or in part from a non-sheet material, such as an injection molded polymer or composite material, an aluminum extrusion, or a composite pultrusion, etc. By incorporating such alternative material structures for the inner beam member 22, the geometry may also be different from Figure 5 and Figure 6 The geometry of the inner beam member 22 is shown. In such further alternatives, the inner beam member 22 or features thereof may be formed via machining, molding, or other processes appropriate to the material selected for forming the alternative material.

[0053] Reference now Figure 7 , illustrates a simulated experimental test result showing the rearward displacement in millimeters (mm) of the bumper reinforcement beam 12 when an increasing force load is applied when subjected to a center pole impact test. Figure 7 The graph in Figure 2 illustrates the results of a simulation test. Figure 8 The illustrated bumper reinforcement beam 12 was compared to a known bumper reinforcement beam design that had the same mass as the tested bumper reinforcement beam in proportion. The results showed a 36% increase in strength (at peak load) and a 92% increase in energy absorption after a displacement of 100 mm. To achieve similar performance levels, other bumper reinforcement beam designs would typically need to have approximately 25% additional mass.

[0054] Figures 8 to 20 Additional examples of reinforcing beams are illustrated, showing Figure 5 and Figure 6 Various alternative features and variations of the reinforcement beams shown. For example, Figure 8 and Fig. 9 The reinforcing beams 112, 212 are illustrated with alternative rib structures as described above. For example, Figure 8 A reinforcing beam 112 is illustrated having an outer beam member 120 with a rear piece 128 having no rear ribs to form a substantially flat rear wall 132 and a front piece 126 having a front wall 130 . Figure 8 Also illustrated is an inner beam member 122 including a groove 154 positioned on an intermediate portion or connecting wall 152 that interconnects between the top wall 134 and the bottom wall 136 .

[0055] Fig. 9The reinforcing beam 212 is illustrated with an outer beam member 220 having a front member 226 without ribs to form a substantially flat front wall 230, but which may have a curved shape or curvature along its length. The outer beam member includes a rear member 228 without ribs to form a substantially flat rear wall 232. The inner beam member 222 includes a groove 254 positioned on an intermediate portion or connecting wall 252 that interconnects between the top wall 234 and the lower wall 236.

[0056] exist Fig.10 In the example shown, the reinforcing beam 312 has a common plate thickness for the outer beam member 320 and the inner beam member 322. Due to the smaller plate thickness of the inner beam member 322, the upper wall 334 and the lower wall 336 are closer together, and the transition curve at the front portion of the upper wall and the lower wall can have a smaller radius of curvature, thereby having a shorter height at the middle portion 352. In the illustrated example, the outer beam member 322 includes a rear piece 328 without ribs to form a substantially flat rear wall 332 and a front piece 326 with ribs forming the front wall 330.

[0057] Similarly, in Fig.11 In the example shown, the reinforcing beams 412 have a common plate thickness, but instead of Fig.10 The 1 mm shown, the reinforcing beam 412 has a thickness of 2 mm, which results in a greater height of the rib 446 formed on the front wall 430 without exceeding the allowable curvature (minimum bending radius) of the sheet material without failure. In the illustrated example, the outer beam member 422 includes a rear piece 428 without ribs to form a substantially flat rear wall 432 and a front piece 426 with ribs forming the front wall 430.

[0058] like Fig.12 As shown, the height of the inner beam member 522 of the reinforcing beam 512 is Fig.10 The example shown is similarly reduced, but to a greater extent. This shorter height of the inner beam member 522 is again due to the inner beam member having a thinner sheet material and, in turn, a greater degree of curvature. In the illustrated example, the outer beam member 522 includes a rear member 528 without ribs to form a substantially flat rear wall 532 and a front member 526 with ribs forming a front wall 530.

[0059] Fig.13 The illustrated example is achieved by inverting the rear flanges 656a, 656b extending integrally from the upper wall 634 and the lower wall 636. Figure 5 and Figure 6 The reinforcement beam shown changes the inner beam member 622. Fig.13As shown, an upper rear flange 656a extends downwardly from the upper wall 634, and a lower rear flange 656b extends upwardly from the lower wall 636. In the illustrated example, the outer beam member 622 includes a rear piece 628 without ribs to form a substantially flat rear wall 632 and a front piece 626 having ribs forming the front wall 630.

[0060] refer to Fig.14 and Fig.15 Examples of reinforcement beams 712, 812 are shown, which each shorten the height of the front wall 730, 830 by eliminating the upper and lower flanges that extend beyond the contour of the hollow interior area. In contrast, the front member 726, 826 is coupled to the rear member 728, 828 of the outer beam member 720, 820 by attaching the upper and lower edges of the front member 726, 826 to the inwardly protruding front flanges 742a, 842a on the rear member 728, 828. Specifically, as shown in FIG. Fig.14 As shown, the front piece 726 is attached to the rearwardly facing surface of the front flange 742a of the rear piece 728. Alternatively, as Fig.15 As shown, the front piece 826 is attached to the forward facing surfaces of the front flanges 842a, 842b of the rear piece 328.

[0061] exist Figures 16 to 19 A further example of a reinforcing beam is shown in , which integrates and eliminates different walls, such as by using a single plate that is roll-formed or otherwise bent to form such different shapes. Fig.16 and Fig.17 As shown, a single plate is used for the bent reinforcement so that the upper and lower walls of the inner beam member are an integral part of the same metal plate as the outer beam member. Fig.16 , the reinforcing beam 912 includes an outer portion 920 having a rear piece 928 forming a generally c-shaped member. The rear piece 928 is free of ribs to form a substantially flat rear wall 932. The outer portion 920 includes a front piece 926 including a front wall 930 including ribs. The plates defining the outer beam member 920 further define the inner beam member 922. The inner portion 922 extends inwardly in front of the rear wall 932 portion and includes a top wall 934 and a rear wall 936 extending between the front wall 930 and the rear wall 932 of the outer portion 920.

[0062] Similar to Fig.17 , a single plate is used to define both the outer portion 1020 and the inner portion 1022 of the reinforcing beam 1012. However, in contrast, the outer portion 1020 includes a rear piece 1028, which also includes a rear wall including a central rib 1032 that follows the C-shape of the inner portion 1022, specifically the top wall 1034 and the lower wall 1036 of the inner portion 1022.

[0063] exist Fig.18In the embodiment, the reinforcing beam 1112 includes an inner beam member 1122 that is constructed as a separate piece and is provided as a rear reinforcement member along portions of the upper wall 1134 and the lower wall 1136 of the rear wall rib 1132. Similarly, and as Fig.19 As illustrated, the reinforcing beam 1212 may include Fig.18 The outer beam member is used in the case of the inner beam member 1122.

[0064] In such Fig. 20 In yet another example shown, the reinforcing beam 1312 may also include an inner beam member 1322 having a corrugation along its length formed in the z-direction in the upper wall 1334 and the lower wall 1336. Such a corrugated configuration may provide increased stability along the upper and lower walls when subjected to stress and receiving collision loads.

[0065] In such Figure 21 to Figure 23 In another example shown, the reinforcing beam 1412 includes an inner beam member 1422 having tapered ends 1460, 1462. The inner beam 1422 includes a forward facing side 1452 or an intermediate wall or connecting wall connecting the upper wall 1434 and the lower wall 1436. The forward facing side 1452 extends adjacent to and generally parallel to the front wall 1430 of the outer beam. The inner beam 1422 also includes a rearward facing side 1464, which generally includes the rearward portions of the upper wall 1434 and the lower wall 1436. The length of the forward facing side 1452 is greater than the length of the rearward facing side 1464. The tapered ends 1460, 1462 connect the ends of the forward facing side 1452 of the inner beam member 1422 to the corresponding ends of the rearward facing side 1464, defining a tapered shape due to the difference in length. As shown in FIG. Fig.23 As shown, the tapered ends 1460, 1462 are angled at approximately 45 degrees relative to the front wall 1430 such that the length of the forward facing side 1452 is longer than the length of the rearward facing side 1464. The tapered shape of the ends 1460, 1462 can provide a gradual reduction in stress concentrations and a reduction in strength at the ends of the inner beam member 1422 during an impact. The gradual reduction in strength can provide increased stability along the beam 1412 when subjected to stress and receiving impact loads.

[0066] Similarly, if Figure 24 to Figure 26As shown, the reinforcing beam 1512 includes an inner beam member 1522 having tapered ends 1560, 1562. The inner beam 1522 includes a forward facing side 1452 or an intermediate wall or connecting wall connecting the upper wall 1534 and the lower wall 1536. The forward facing side 1552 extends adjacent to and generally parallel to the front wall 1530 of the outer beam. The inner beam 1522 also includes a rearward facing side 1564, which generally includes the rearward portions of the upper wall 1534 and the lower wall 1536. The tapered ends 1560, 1562 connect the ends of the forward facing side 1552 of the inner beam member 1522 to the corresponding ends of the rearward facing side 1564, defining a tapered shape due to the difference in length. As shown in FIG. Fig.26 As shown, the tapered ends 1560, 1562 are angled at approximately 45 degrees relative to the front wall 1530 such that the length of the forward facing side 1552 is longer than the length of the rearward facing side 1564. The tapered shape of the ends 1560, 1562 can provide a gradual reduction in stress concentration and a reduction in strength at the ends of the inner beam member 1522 during an impact. The gradual reduction in strength can provide increased stability along the beam 1512 when subjected to stress and receiving impact loads.

[0067] For purposes of this disclosure, the term "couple" (in all its forms, couple, coupling, coupled, etc.) generally means the joining of two components (mechanical) directly or indirectly to one another. Such joining may be fixed in nature or removable in nature; may be achieved with the two components (mechanical) and any additional intermediate members being integrally formed as a single unitary structure with one another or with the two components; and may be permanent in nature or may be removable or releasable in nature, unless otherwise specified.

[0068] The articles "a", "an" and "the" are intended to indicate the presence of one or more of the elements in the preceding description. The terms "comprising", "including" and "having" are intended to be inclusive and mean that there may be additional elements in addition to the listed elements. Furthermore, it should be understood that reference to "one embodiment" or "embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional implementations that also include the described features. Furthermore, the terms "first", "second", etc., as used herein, do not indicate any order, quantity, or importance, but are used to indicate elements from another.

[0069] The numbers, percentages, ratios, or other values ​​described herein are intended to include that value, as well as other values ​​that are "about" or "approximately" the stated value, as understood by those of ordinary skill in the art encompassed by the embodiments of the present disclosure. Therefore, the values ​​should be interpreted as being broad enough to include values ​​that are at least close enough to the stated value to perform the desired function or achieve the desired result. For example, the terms "approximately," "about," and "substantially" can refer to amounts that are less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount.

[0070] Furthermore, it should be understood that any directions or reference frames in the foregoing description are merely relative directions or motions. For example, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," "inner," "outer," and their derivatives should be understood to mean relative directions or motions. Figure 1 The embodiments of the present invention are not limited to the orientation shown in the drawings. However, it should be understood that various alternative orientations can be provided unless expressly specified 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 of the inventive concepts defined in the appended claims. Therefore, the specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting unless expressly stated in the claims.

[0071] Without departing from the principles of the present invention, the specifically described embodiments may be changed and modified, and the principles of the present invention are limited only by the scope of the appended claims interpreted according to the principles of patent law. The present disclosure has been described in an illustrative manner, and it should be understood that the terms used are intended to be descriptive rather than restrictive. In accordance with the above teachings, there may be many modifications and variations of the present disclosure, and the present disclosure may be implemented in a manner different from that specifically described.

Claims

1. A bumper reinforcement beam, the bumper reinforcement beam being configured to be supported by a crush box at a vehicle frame, the bumper reinforcement beam comprises: an outer beam having an elongated hollow body formed from a metal sheet and configured to extend transversely across the crush boxes, the hollow body having a front wall and a rear wall extending along a length defined between a first end and a second end of the hollow body; and an inner beam disposed along an intermediate section of the outer beam, the inner beam having an upper wall and a lower wall, each of the upper wall and the lower wall extending between the front wall and the rear wall of the outer beam.

2. The bumper reinforcement beam according to claim 1, wherein at least one of the front wall and the rear wall of the outer beam includes at least one rib extending along the length of the outer beam.

3. The bumper reinforcement beam according to claim 1, wherein the inner beam includes opposite ends that define therebetween a length less than one half of the length of the outer beam.

4. The bumper reinforcement beam according to claim 1, wherein the inner beam is formed from a second metal sheet having a thickness greater than the thickness of the metal sheet of the outer beam.

5. The bumper reinforcement beam according to claim 1, wherein the inner beam includes an intermediate portion interconnected between the upper wall and the lower wall to together define a channel along the inner beam.

6. The bumper reinforcement beam according to claim 5, wherein the intermediate portion of the inner beam is coupled to the front wall of the outer beam.

7. The bumper reinforcement beam according to claim 1, wherein the inner beam includes rear flanges integrally extending from rear portions of the upper wall and the lower wall.

8. The bumper reinforcement beam according to claim 7, wherein the rear wall includes a pair of rear ribs configured to hold the rear flanges.

9. The bumper reinforcement beam according to claim 1, wherein the outer beam includes a front member and a rear member, the front member including the front wall and the rear member including the rear wall, wherein the front member and the rear member each include upper flanges and lower flanges, and wherein the front member and the rear member are attached together along corresponding upper and lower flanges to enclose a hollow interior of the outer beam.

10. The bumper reinforcement beam according to claim 9, wherein the upper flanges of the front beam member and the upper flanges of the rear beam member project upwardly from the hollow interior of the outer beam, and the lower flanges of the front beam member and the lower flanges of the rear beam member project downwardly from the hollow interior of the outer beam.

11. The bumper reinforcement beam according to claim 1, wherein the upper wall and the lower wall of the inner beam extend rearwardly at an angle less than 40 degrees with respect to a normal to a planar extent of the front wall.

12. The bumper reinforcement beam according to claim 11, wherein the upper wall of the inner beam extends rearwardly and upwardly at an angle less than 20 degrees with respect to a normal to a planar extent of the front wall, and the lower wall of the inner beam extends rearwardly and downwardly at an angle less than 20 degrees with respect to a normal to a planar extent of the front wall.

13. A bumper reinforcement beam, the bumper reinforcement beam being configured to be supported by a crush box at a vehicle frame, the bumper reinforcement beam comprising: a front beam member, the front beam member including a front wall; a rear beam member, the rear beam member including a rear wall and an upper flange and a lower flange, the upper flange and the lower flange being attached along corresponding upper and lower edges of the front beam member to define an elongated hollow body having a length configured to span between crush boxes; and an inner beam member, the inner beam member being attached between the front beam member and the rear beam member and including an upper wall and a lower wall, the upper wall and the lower wall each extending between the front wall and the rear wall, wherein the length of the inner beam member is less than one-half of the length of the elongated hollow body.

14. The bumper reinforcement beam according to claim 13, wherein the upper wall and the lower wall of the inner beam extend rearward at an angle of less than 40 degrees with respect to a normal to a planar extent of the front wall.

15. The bumper reinforcement beam according to claim 14, wherein the upper wall of the inner beam extends rearward and upward at an angle of less than 20 degrees with respect to a normal to a planar extent of the front wall.

16. The bumper reinforcement beam according to claim 14, wherein the lower wall of the inner beam extends rearward and downward at an angle of less than 20 degrees with respect to a normal to a planar extent of the front wall.

17. The bumper reinforcement beam according to claim 13, wherein the front beam member and the rear beam member are attached together along corresponding upper and lower flanges, and the front beam member and the rear beam member are each formed from a separate metal plate.

18. The bumper reinforcement beam according to claim 17, wherein the upper flange of the front beam member and the upper flange of the rear beam member project upward from a hollow interior of the hollow body.

19. The bumper reinforcement beam according to claim 17, wherein the lower flange of the front beam member and the lower flange of the rear beam member project downward from the hollow interior of the hollow body.

20. The bumper reinforcement beam according to claim 13, wherein the rear beam member includes an upper wall and a lower wall, the upper wall and the lower wall together with the rear wall defining a C-shaped cross-section.

21. The bumper reinforcement beam according to claim 13, wherein the rear wall of the rear beam member includes an attachment surface adapted to be attached to the crush box.

22. The bumper reinforcement beam according to claim 13, wherein the front wall includes a pair of front ribs extending along a length of the front beam member.

23. The bumper reinforcement beam according to claim 22, wherein the rear wall includes a pair of rear ribs extending along a length of the rear beam member.

24. The bumper reinforcement beam according to claim 23, wherein the inner beam member includes a pair of rear flanges integrally extending from rear portions of the upper wall and the lower wall, and the rear ribs are configured to hold the rear flanges.

25. The bumper reinforcement beam according to claim 13, wherein the front beam member and the rear beam member are formed of a metal sheet, the inner beam member is formed of a second metal sheet, and the thickness of the second metal sheet is greater than the thickness of the metal sheet of the front beam member and the rear beam member.

26. The bumper reinforcement beam according to claim 13, wherein the inner beam member includes an intermediate portion that interconnects between the upper wall and the lower wall to define a passage along the inner beam member.

27. A bumper reinforcement beam for a vehicle, the bumper reinforcement beam comprising: an outer beam member including an outer wall; an inner beam member including an inner wall and upper and lower flanges that are attached along respective upper and lower edges of the outer beam member to define an elongate hollow body having a length defined between opposite ends of the outer beam member; and an inner beam member attached between the outer beam member and the inner beam member and including a C-shaped cross-section defining upper and lower shear walls that each extend between the outer wall and the inner wall, wherein the length of the inner beam member is less than one-half of the length of the elongate hollow body.

28. The bumper reinforcement beam according to claim 27, wherein the upper and lower shear walls of the inner beam divide an internal volume of the hollow body to form a plurality of elongate hollow regions.

29. The bumper reinforcement beam according to claim 27, wherein at least one of the outer wall and the inner wall includes at least one rib extending along the length of the elongate hollow body.

30. The bumper reinforcement beam according to claim 27, wherein the outer beam member and the inner beam member are formed of a metal sheet, the inner beam member is formed of a second metal sheet, and the thickness of the second metal sheet is greater than the thickness of the metal sheet of the outer beam member and the inner beam member.

31. The bumper reinforcement beam according to claim 27, wherein the inner beam member includes an intermediate portion that interconnects between the upper and lower shear walls to together define the C-shaped cross-section.

32. The bumper reinforcement beam according to claim 31, wherein the intermediate portion of the inner beam member is connected to the outer wall.

33. The bumper reinforcement beam according to claim 27, wherein the inner beam member includes a rear flange extending from a rear portion of the upper and lower shear walls.

34. The bumper reinforcement beam according to claim 33, wherein the inner wall includes a set of inner wall ribs configured to hold the rear flange.

35. The bumper reinforcement beam according to claim 27, wherein the upper and lower shear walls of the inner beam member extend rearwardly at an angle less than 40 degrees relative to a normal to a planar extent of the outer wall.

36. The bumper reinforcement beam according to claim 35, wherein the upper shear wall of the inner beam member extends backward and upward at an angle of less than 20 degrees with respect to the normal of the planar extent of the outer side wall, and the lower shear wall of the inner beam member extends backward and downward at an angle of less than 20 degrees with respect to the normal of the planar extent of the outer side wall.

37. The bumper reinforcement beam according to claim 27, wherein the upper flange of the inner beam member and the upper flange of the outer beam member project upward from the elongated hollow body, and the lower flange of the inner beam member and the lower flange of the outer beam member project downward from the elongated hollow body.

38. The bumper reinforcement beam according to claim 27, wherein the elongated hollow body has a length configured to span between the crash boxes, and the inner side wall of the inner beam member includes an attachment surface adapted to be attached to the crash box.

39. The bumper reinforcement beam according to claim 27, wherein the inner beam member includes a first length attached to the outer beam member and includes a second length attached to the inner beam member.

40. The bumper reinforcement beam according to claim 27, wherein the inner beam member includes a tapered end that connects the end of the first length to the end of the second length.

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